2017 Tmax530DX 서비스매뉴얼 개선판

2017
SERVICE MANUAL
XP530E-A
XP530-A
XP530D-A
BV1-28197-E0
EAS20002
XP530E-A/XP530-A/XP530D-A
SERVICE MANUAL
©2017 by Yamaha Motor Co., Ltd.
First edition, March 2017
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS20003
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
Designs and specifications are subject to change without notice.
EAS30001
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential per-
sonal injury hazards. Obey all safety messages that follow this symbol
to avoid possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could

WARNING result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid

NOTICE damage to the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.

EAS20004
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
1
OIL PUMP OIL PUMP
EAS20054 EAS30337
OIL PUMP CHECKING THE OIL PUMP

1. Check:
Removing the oil pump assembly • Oil pump driven gear “1”
• Oil pump housing 2 “2”
Cracks/damage/wear → Replace the oil
pump assembly.
3 EAS30342
ASSEMBLING THE OIL PUMP

1. Lubricate:
• Inner rotor
• Outer rotor
• Oil pump shaft
4
LT
(with the recommended lubricant)
2. Check: Recommended lubricant

10 N・m (1.0 kgf・m, 7.4 lb・ft)
• Oil pump operation Engine oil
Rough movement → Repeat steps (1) and
(2) or replace the oil pump assembly. 2. Install:
• Inner rotors
1
TIP
When installing the inner rotor, align the pins “1”
in the oil pump shaft with the grooves “a” in the
4 6
3
2
inner rotor.
7
(3)
1
5 5
10 N・m (1.0 kgf・m, 7.4 lb・ft)
EAS30338
CHECKING THE RELIEF VALVE

6 Order Job/Parts to remove
Bottom side cowling/Side panel/Bottom center
cowling
Q’ty Remarks
Refer to “GENERAL CHASSIS (1)” on page
4-1.
1. Check:
• Relief valve body a
a
1
Damage/wear → Replace.
Center cover/Fuel tank cover assembly/Side Refer to “GENERAL CHASSIS (2)” on page
cover (left)/Footboard (left) 4-11. EAS30742 3. Check:
V-belt case air filter element (left)/Generator CHECKING THE OIL PIPES • Oil pump operation
cover protector/Water pump inlet pipe/Water Refer to “WATER PUMP” on page 6-9. 1. Check: Refer to “CHECKING THE OIL PUMP” on
pump outlet pipe/Water pump assembly
• Oil pipe page 5-61.
Generator cover/Generator rotor/Starter clutch Refer to “GENERATOR AND STARTER
gear CLUTCH” on page 5-44. • Oil delivery pipe EAS30343
1
2
Oil pump assembly
Oil pump drive chain
1
1
Damage → Replace.
Obstruction → Wash and blow out with com-
pressed air.
INSTALLING THE OIL PUMP
1. Install: 2
3 Gasket 2 • Oil pump assembly
4 Oil delivery pipe 1 EAS30785
5 Oil pipe 1 CHECKING THE OIL PUMP DRIVE CHAIN Oil pump bolt
6 Relief valve assembly 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
1. Check:
T.
R.
• Oil pump drive chain ECA13890
Cracks/stiffness → Replace the oil pump NOTICE

chain and oil pump assembly as a set. After tightening the bolts, make sure the oil
pump turns smoothly.
5-59 5-61
EAS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil

G
Filling fluid Molybdenum disulfide oil

M
Lubricant Brake fluid

BF
Special tool B Wheel bearing grease
Tightening torque LS Lithium-soap-based grease

T.
R.
Wear limit, clearance M Molybdenum disulfide grease
Engine speed S Silicone grease
Electrical data Apply locking agent (LOCTITE®).

LT
Engine oil New Replace the part with a new one.

E
Silicone fluid
S
TABLE OF CONTENTS
EAS10003
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
ELECTRICAL SYSTEM 8
TROUBLESHOOTING 9
GENERAL INFORMATION
IDENTIFICATION..............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER ......................................................1-1
1
MODEL LABEL...........................................................................................1-1
FEATURES .......................................................................................................1-2
YCC-T (Yamaha Chip Controlled Throttle).................................................1-2
OUTLINE OF THE CRUISE CONTROL SYSTEM (for XP530D-A) ...........1-4
OUTLINE OF THE TCS (Traction Control System)....................................1-9
MULTI-FUNCTION DISPLAY...................................................................1-12 2
IMPORTANT INFORMATION .........................................................................1-22
PREPARATION FOR REMOVAL AND DISASSEMBLY..........................1-22
REPLACEMENT PARTS..........................................................................1-22
GASKETS, OIL SEALS AND O-RINGS ...................................................1-22
LOCK WASHERS/PLATES AND COTTER PINS ....................................1-22
3
BEARINGS AND OIL SEALS ...................................................................1-22
CIRCLIPS .................................................................................................1-23
RUBBER PARTS......................................................................................1-23
4
BASIC SERVICE INFORMATION ..................................................................1-24
QUICK FASTENERS................................................................................1-24
5
ELECTRICAL SYSTEM............................................................................1-25
SPECIAL TOOLS ...........................................................................................1-29
6
7
8
9
IDENTIFICATION
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the right side of the frame.
EAS30003
MODEL LABEL
The model label “1” is affixed to the storage box.
This information will be needed to order spare
parts.
1-1
FEATURES
EAS20008
FEATURES
EAS30852
YCC-T (Yamaha Chip Controlled Throttle)

Mechanism characteristics
Yamaha developed the YCC-T system employing the most advanced electronic control technologies.
Electronic control throttle systems have been used on automobiles, but Yamaha has developed a fast-
er, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed
system has a high-speed calculating capacity that produces computations of running conditions every
1/1000th of a second.
The YCC-T system is designed to respond to the throttle action of the rider by having the ECU instan-
taneously calculate the ideal throttle valve opening and generate signals to operate the motor-driven
throttle valves and thus actively control the intake air volume.
The ECU contains two CPUs with a capacity about five times that of conventional units, making it pos-
sible for the system to respond extremely quickly to the slightest adjustments made by the rider. In par-
ticular, optimized control of the throttle valve opening provides the optimum volume of intake air for
easy-to-use torque, even in a high-revving engine.
Aims and advantages of using YCC-T
• Increased engine power
By shortening the air intake path, higher engine speed is possible  Increased engine power.
• Improved driveability
Air intake volume is controlled according to the operating conditions  Improved throttle response to
meet engine requirement.
Driving force is controlled at the optimal level according to the engine speed  Improved throttle con-
trol.
• Engine braking control
Due to the throttle control, optimal engine braking is made possible.
• Simplified idle speed control (ISC) mechanism
The bypass mechanism and ISC actuator are eliminated  A simple mechanism is used to maintain
a steady idle speed.
• Reduced weight
Compared to using a sub-throttle mechanism, weight is reduced.
4
2
1. Throttle valves
2. Throttle servo motor
3. Throttle position sensor
4. Accelerator position sensor
1-2
FEATURES
YCC-T system outline
3
1
2
5
6
7
8

4. ECU (Engine Control Unit)
5. Sensor input
6. Crankshaft position sensor
7. Rear wheel sensor
8. Coolant temperature sensor
1-3
FEATURES
EAS30940
OUTLINE OF THE CRUISE CONTROL SYSTEM (for XP530D-A)

This model is equipped with a cruise control system designed to maintain a set cruising speed. Be-
cause the vehicle is equipped with the YCC-T system, the cruise control system can be controlled elec-
tronically. Based on the signals that are received from the sensors and switches, the ECU calculates
the required throttle valve opening and operates the throttle servo motor to control the throttle valves.
Because the system allows the rider to maintain a set cruising speed without operating the throttle, the
system reduces the burden of maintaining a constant speed during long-distance touring. In addition,
the cruise control system is equipped with a self-diagnosis function.
3
6
4
5 7
13
12 8
11
10 9
1. Meter assembly
3. Rear brake light switch
4. Cruise control setting switch
5. Cruise control power switch
6. Front brake light switch
7. Engine stop switch
8. Grip cancel switch
10.Throttle servo motor
11.Throttle position sensor
12.Crankshaft position sensor
13.Rear wheel sensor
1-4
FEATURES
The cruise control system is designed to maintain a set cruising speed between about 50 km/h (31 mi/h)
and 140 km/h (87 mi/h).
EWA17451
WARNING
• Improper use of the cruise control system may result in loss of control, which could lead to an
accident. Do not activate the cruise control system in heavy traffic, poor weather conditions,
or among winding, slippery, hilly, rough or gravel roads.
• When traveling uphill or downhill, the cruise control system may not be able to maintain the
set cruising speed.
• To prevent accidentally activating the cruise control system, turn it off when not in use. Make
sure that the cruise control system indicator light is off.
RES
PASS
SET
1
3
4
2
1. Cruise control setting switch “RES+/SET–” 3. Cruise control system indicator light “ ”
2. Cruise control power switch “ ” 4. Cruise control setting indicator light “SET”
Activating and setting the cruise control system

1. Push the cruise control power switch “ ” to turn on the system. The cruise control system indicator
light “ ” will come on.
2. Push the “SET–” side of the cruise control setting switch to activate the cruise control system. Your
current traveling speed will become the set cruising speed. The cruise control setting indicator light
“SET” will come on.
Adjusting the set cruising speed
While the cruise control system is operating, push the “RES+” side of the cruise control setting switch
to increase the set cruising speed or the “SET–” side to decrease the set speed.
TIP
Pushing the setting switch once will change the speed in increments of approximately 2.0 km/h (1.2
mi/h). Holding down the “RES+” or “SET–” side of the cruise control setting switch will increase or de-
crease the speed continuously until the switch is released.
You can also manually increase your traveling speed using the throttle. After you have accelerated, you
can set a new cruising speed by pushing the “SET–” side of the setting switch. If you do not set a new
cruising speed, when you return the throttle grip, the vehicle will decelerate to the previously set cruising
speed.
1-5
FEATURES
Deactivating the cruise control system

Perform one of the following operations to cancel the set cruising speed. The “SET” indicator light will
go off.
• Turn the throttle grip past the closed position in the deceleration direction.
MOD
b a
E
a. Closed position b. Cruise control cancel direction
• Apply the front or rear brake.

TIP
Traveling speed decreases as soon as the cruise control system is deactivated; unless the throttle grip
is turned.
Using the resume function
Push the “RES+” side of the cruise control setting switch to reactivate the cruise control system. The
traveling speed will return to the previously set cruising speed. The “SET” indicator light will come on.
EWA17460
WARNING
It is dangerous to use the resume function when the previously set cruising speed is too high
for current conditions.
Turning off the cruise control system
Push the cruise control power switch “ ” to turn off the cruise control system. The “ ” indicator light
and the “SET” indicator light will turn off.
TIP
Whenever the cruise control system or the vehicle power is turned off, the previously set cruising speed
is erased. You will not be able to use the resume function until a new cruising speed has been set.
Automatic deactivation of the cruise control system
The cruise control system is electronically controlled and linked with other control systems. The cruise
control system will automatically deactivate under the following conditions:
• The cruise control system is not able to maintain the set cruising speed (such as when going up a
steep hill).
• Wheel slip or wheel spin is detected. (If the traction control system is on, traction control will engage.)
• Engine trouble, etc.
If the cruise control system is automatically deactivated, the “ ” indicator light will turn off and the “SET”
indicator light will flash for 4 seconds.
If the cruise control system was automatically deactivated, please stop and confirm that your vehicle is
in good operating condition before continuing on.
When traveling on roads with steep grades, the cruise control system may not be able to maintain the
set cruising speed.
• When going uphill, the actual traveling speed may become lower than the set cruising speed. If this
occurs, accelerate to the desired traveling speed using the throttle.
• When going downhill, the actual traveling speed may become higher than the set cruising speed. If
this occurs, the setting switch cannot be used to adjust the set cruising speed. To reduce the traveling
speed, apply the brakes. When the brakes are applied, the cruise control system will deactivate.
1-6
FEATURES
Meter displays during cruise control system operation
A D
a a c
B C
A. Cruise control system is activated (cruising a. Condition for automatically deactivating

speed is set) cruise control system is detected
B. Cruise control system is turned off (cruise b. 4 seconds elapse (during this time, input from
control setting indicator light “SET” flashes) the cruise control power switch “ ” will not
C. Cruise control system is turned off be received)
D. Cruise control system is turned on (cruising c. Cruise control power switch “ ” “ON”
speed is not set) d. Cruising speed is set
Self-diagnosis device
3 2 1
1. Engine trouble warning light “ ” 3. Cruise control setting indicator light “SET”
2. Cruise control system indicator light “ ”
The cruise control system will also become deactivated when an irregularity with any of the vehicle sys-
tems is detected. The cruise control setting indicator light “SET” will go off and the cruise control system
indicator light “ ” will flash. You will not be able to use the cruise control system while the engine trou-
ble warning light is on, or while the cruise control system is malfunctioning.
ECA23590
NOTICE
If the engine trouble warning light come on, the vehicle should be checked as soon as possible
in order to avoid engine damage.
1-7
FEATURES
TIP
• If the cruise control system turned off because a malfunction was detected by the FI self-diagnosis,
the cruise control power switch “ ” must be pushed once before the system can return to the normal
operating condition.
• If a switch for the cruise control system is malfunctioning (fault code No. P056C and P0564), the en-
gine trouble warning light will not come on because the normal operation of the vehicle is not affected.
Meter displays during cruise control system operation
A E
a
F G
B C
d c
c b b
D D
A. Cruise control system is activated (cruising a. Malfunction occurs

speed is set) b. Cruise control power switch “ ” “OFF”
B. Cruise control system is turned off (engine c. Cruise control power switch “ ” “ON”
trouble warning light “ ” comes on, cruise
control system is deactivated, and cruise d. After the cause of the malfunction has been
control system indicator light “ ” flashes) repaired, delete the fault code by using the
Yamaha diagnostic tool.
C. Cruise control system is turned off (engine
trouble warning light “ ” goes off, cruise e. Cruising speed is set
control system is deactivated, and cruise
control system indicator light “ ” flashes)
D. Cruise control system is turned off
E. Cruise control system is turned on (cruising
speed is not set)
F. Malfunction detected by FI self-diagnosis
G. Malfunction not detected by FI self-diagnosis
1-8
FEATURES
TIP
This section explains the operation of the cruise control system according to the meter displays when
a malfunction is detected in the fuel injection system.
EAS30855
OUTLINE OF THE TCS (Traction Control System)

The traction control system controls excessive spinning (slipping) of the rear wheel when accelerating
on slippery surfaces, such as unpaved or wet roads.
The ECU monitors the front and rear wheel speeds using the signals from the front and rear wheel sen-
sors, and detects rear wheel slipping according to the difference between the wheel speeds. If the slip-
ping exceeds the preset value, the ECU controls the slipping using integrated control of the ignition
timing, fuel cut-off, and throttle valve opening of the YCC-T system.
The traction control system can be set to one of three operation modes or turned off.
TCS (Traction control system) layout
9 1 2 3
7 6 5
1. Traction control system indicator light

3. Fuel injector
5. Spark plugs
6. Ignition coil
7. Front wheel sensor
8. ECU
9. ABS ECU
1-9
FEATURES
TCS (Traction control system) block diagram

The signals from the front and rear wheel sensors are sent to the ECU through the ABS ECU, and the
ECU calculates the amount of slip according to the difference between the detected front and rear
wheel speeds.
If the amount of slip exceeds the preset value, the ECU controls the ignition timing, fuel cut-off, and
throttle valve opening of the YCC-T system so that the amount of slip is less than the preset value. The
traction control system indicator light in the meter assembly flashes when the traction control system
has activated.
3 E
1 A
B C F
D
2 A
G

3. ABS ECU
4. ECU
A. Signal conversion
B. Slip amount calculation
C. Exceeds preset value
D. Actuator control
E. Fuel cut-off
F. Ignition timing (retarded)
G. Traction control system indicator light
(flashes)
H. YCC-T motor throttle valve opening
(decreased)
1-10
FEATURES
Traction control system

The traction control system (TCS) helps maintain traction when accelerating on slippery surfaces, such
as unpaved or wet roads. If sensors detect that the rear wheel is starting to slip (uncontrolled spinning),
the traction control system assists by regulating engine power as needed until traction is restored.
When traction control has engaged, the “ ” indicator light will flash. You may notice changes in engine
response or exhaust sounds.
EWA18860
WARNING
The traction control system is not a substitute for riding appropriately for the conditions. Trac-
tion control cannot prevent loss of traction due to excessive speed when entering turns, when
accelerating hard at a sharp lean angle, or while braking, and cannot prevent front wheel slip-
ping. As with any vehicle, approach surfaces that may be slippery with caution and avoid espe-
cially slippery surfaces.
Setting the traction control system
1. Traction control system indicator light “ ”

When the vehicle is turned on, traction control is automatically turned on.
To turn the traction control system off, refer to “Setting mode” on page 1-16.
TIP
Turn the traction control system off to help free the rear wheel if the vehicle gets stuck in mud, sand, or
other soft surfaces.
ECA19650
NOTICE
Use only the specified tires. Using different sized tires will prevent the traction control system
from controlling tire rotation accurately.
Resetting the traction control system
The traction control system will automatically disable under certain conditions; such as when a sensor
fault is detected, or when only one wheel is allowed to rotate for more than a few seconds. Should this
happen, the “ ” indicator light will come on, and possibly the “ ” warning light, too.
TIP
When the vehicle is on the centerstand, do not rev the engine for an extended period of time. Otherwise,
the traction control system will automatically disable and need to be reset.
If the traction control system automatically disables, try resetting it as follows.
1. Stop the vehicle and turn it off completely.
2. Wait a few seconds and then turn the vehicle power on.
3. The “ ” indicator light should turn off and the system be enabled.
TIP
If the “ ” indicator light remains on after resetting, check the fuel injection system (Refer to “FUEL IN-
JECTION SYSTEM” on page 8-55).
4. Check the vehicle and turn off the “ ” warning light.
1-11
FEATURES
EAS30618
The fuel meter indicates the amount of fuel in the
MULTI-FUNCTION DISPLAY fuel tank. The display segments of the fuel meter
disappear from “F” (full) towards “E” (empty) as
4 2 the fuel level decreases. When the last segment
starts flashing, refuel as soon as possible.
3 5
TIP
If a problem is detected in the fuel meter electri-
2 cal circuit, the fuel meter will flash repeatedly.
6
Check the vehicle.
1 Coolant temperature meter
1. Information display
2. Function display
3. Fuel meter
4. Clock
5. Drive mode display (XP530-A, XP530D-A)
6. Coolant temperature meter
1
2
1. Coolant temperature meter
The coolant temperature varies with changes in
3 the weather and engine load. If the top segment
starts flashing, the information display automati-
1 cally changes to “C-TEMP” and “Hi” flashes.
Stop the vehicle and let the engine cool.
TIP
The information display cannot be changed
1. Oil change indicator “Oil” while the engine is overheating.
2. V-belt replacement indicator “V-Belt”
ECA10022
3. Eco indicator “ECO”
NOTICE
EWA12313
Do not continue to operate the engine if it is
WARNING
overheating.
Be sure to stop the vehicle before making
any setting changes to the multi-function Eco indicator
display. Changing settings while riding can
distract the operator and increase the risk of
an accident.
Fuel meter
1
1. Eco indicator “ECO”

This indicator comes on when the vehicle is be-
ing operated in an environmentally friendly, fuel-
efficient manner. The indicator goes off when
1. Fuel meter the vehicle is stopped.
1-12
FEATURES
TIP Oil change indicator “Oil”

Consider the following tips to reduce fuel con-
sumption:
• Avoid high engine speeds during acceleration.
• Travel at a constant speed.
Drive mode display (XP530-A, XP530D-A)
1
1
1. Oil change indicator “Oil”
This indicator flashes at the initial 1000 km (600
mi), then at 5000 km (3000 mi) and every 5000
km (3000 mi) thereafter to indicate that the en-
gine oil should be changed.
1. Drive mode display After changing the engine oil, reset the oil
change indicator. To reset the oil change indica-
This display indicates which drive mode has
tor, refer to “Setting mode” on page 1-16.
been selected: “S” sporty or “T” touring.
If the engine oil is changed before the oil change
V-belt replacement indicator “V-Belt”
indicator “Oil” flashes (i.e. before the periodic oil
change interval has been reached), the indicator
“Oil” must be reset after the oil change for the
next periodic oil change to be indicated at the
1 correct time.
Function display
1. V-belt replacement indicator “V-Belt”

This indicator flashes every 20000 km (12500
mi) when the V-belt needs to be replaced.
After changing the V-belt, reset the V-belt re-
placement indicator. To reset the V-belt replace-
ment indicator, refer to “Setting mode” on page Push the “MENU” switch for one second to
1-16. switch the display between the windshield ad-
If the V-belt is changed before the V-belt re- justing function, grip warmer adjusting function,
placement indicator “V-Belt” flashes (i.e. before seat heater adjusting function, and information
the periodic V-belt change interval has been display selection function.
reached), the indicator “V-Belt” must be reset af- TIP
ter the V-belt change for the next periodic V-belt • For XP530D-A: The windshield adjusting func-
change to be indicated at the correct time. tion, grip warmer adjusting function, seat heat-
er adjusting function can be selected.
• For XP530E-A, XP530-A: The grip warmer and
seat heater requires an accessory part and
cannot be selected.
Adjusting the windshield position
To move the windshield up, push the “ ” side of
the select switch. To move the windshield down,
1-13
FEATURES
push the “ ” side of the select switch. or higher, do not set the seat heater to the
Adjusting the grip warmer high setting.
This vehicle can be equipped with grip warmers, • If the seat becomes worn or damaged, stop
which can only be used when the engine is run- using the seat heater and replace the seat.
ning. There are 4 grip warmer settings. Information display
Setting Display
Off
Low
Middle
High
To increase the grip warmer temperature, push

the “ ” side of the select switch. To decrease There are 3 information display pages. The in-
the grip warmer temperature, push the “ ” side formation display page can be switched by using
of the select switch. the select switch.
ECA17931 The following items can be shown in the infor-
NOTICE mation displays:
• Be sure to wear gloves when using the grip • odometer
warmers. • tripmeters
• If the ambient temperature is 20 C (68 F) • fuel reserve tripmeter
or higher, do not set the grip warmer to the • estimated traveling range
high setting. • ambient temperature
• If the handlebar grip or throttle grip be- • average fuel consumption
comes worn or damaged, stop using the • instantaneous fuel consumption
grip warmers and replace the grips. The items shown in each information display
page can be customized. (Refer to “Setting
Adjusting the seat heater
mode” on page 1-16.)
This vehicle can be equipped with a seat heater,
Odometer:
which can only be used when the engine is run-
ning. There are 4 seat heater settings.
Setting Display
Off
The odometer shows the total distance traveled
Low by the vehicle.
Tripmeter(s):
Middle
High
To increase the seat heater temperature, push

the “ ” side of the select switch. To decrease
the seat heater temperature, push the “ ” side
of the select switch.
ECA23980
NOTICE
• Be sure to wear protective clothing that
covers your hip and legs when using the “TRIP1” and “TRIP2” show the distance traveled
seat heater. since they were last set to zero.
• If the ambient temperature is 20 C (68 F)
1-14
FEATURES
bient temperature.
TIP
• –9 C will be displayed even if the detected
temperature is lower.
• 50 C will be displayed even if the detected
When approximately 3.0 L (0.79 US gal, 0.66 temperature is higher.
Imp.gal) of fuel remains in the fuel tank, the last • The accuracy of the temperature reading may
segment of the fuel meter starts flashing. In ad- be affected when riding under 20 km/h (12
dition, the information display will automatically mi/h) or when stopped at traffic signals and rail-
change to the fuel reserve tripmeter mode “F- road crossings.
TRIP” and start counting the distance traveled Average fuel consumption:
from that point.
In this case, push the select switch to switch the
display in the following order:
F-TRIP Display–1 Display–2 Dis-

play–3 F-TRIP
To reset a tripmeter, use the select switch to se-

lect the information display page that contains
the tripmeter you want to reset. Push the “ ”
side of the select switch for one second so that
the tripmeter flashes, and then push the “ ” The average fuel consumption mode “km/L”,
side of the select switch again for one second “L/100km” or for the UK, “MPG” shows the aver-
while the tripmeter is flashing. age fuel consumption since the display was last
If you do not reset the fuel reserve tripmeter reset.
manually, it will reset automatically after refuel- • “km/L” shows the average distance that can be
ing and traveling 5 km (3 mi). traveled on 1.0 L of fuel.
TIP • “L/100km” shows the average amount of fuel
• The odometer will lock at 999999. necessary to travel 100 km.
• The tripmeters will reset and continue counting • For the UK: “MPG” shows the average dis-
after 9999.9 is reached. tance that can be traveled on 1.0 Imp.gal of fu-
• Display cannot switch to setting mode display el.
when the “F-TRIP” indicated. To reset the average fuel consumption, use the
select switch to select the information display
Estimated traveling range: page that contains the average fuel consump-
tion display. Push the “ ” side of the select
switch so that the average fuel consumption dis-
play flashes, and then push the “ ” side of the
select switch again for 1 seconds while the dis-
play is flashing.
The estimated distance that can be traveled with
TIP
the remaining fuel under the current riding con- After resetting the average fuel consumption dis-
ditions is shown. play, “– –.–” will be shown until the vehicle has
Ambient temperature: traveled 1 km (0.6 mi).
ECA25730
NOTICE
If there is a malfunction, “– –.–” will be con-
tinuously displayed. Check the vehicle.
This display shows the ambient temperature
from –9 C to 50 C in 1 C increments. The tem-
perature displayed may vary from the actual am-
1-15
FEATURES
Instantaneous fuel consumption: return to the normal display, push the “MENU”
switch again for at least 2 seconds.
Display Description
This function allows you to set
Grip Warmer the low, middle, and high set-
tings to 10 temperature levels.
Seat Heater the low, middle, and high set-
tings to 10 temperature levels.
This function allows you to
Traction Control switch the traction control sys-
The instantaneous fuel consumption display tem on or off.
mode “km/L”, “L/100km” or for the UK, “MPG” This function allows you to
shows the fuel consumption under current riding check and reset the “OIL” oil
change interval (distance trav-
conditions. Maintenance eled), “V-Belt” V-Belt change
• “km/L” shows the distance that can be traveled interval (distance traveled), and
on 1.0 L of fuel. the “FREE” maintenance inter-
• “L/100km” shows the amount of fuel necessary vals.
to travel 100 km. This function allows you to
• For the UK: “MPG” shows the distance that can switch the fuel consumption
units can be switched between
be traveled on 1.0 Imp.gal of fuel. Unit “L/100km” and “km/L”.
TIP For the UK: This function does
• Instantaneous fuel consumption cannot be re- not indicate on setting mode
set. display.
• If traveling at speeds under 10 km/h (6 mi/h), “– This function allows you to
–.–” will be displayed. Display change the items shown in 3
information displays.
ECA25730
NOTICE This function allows you to

adjust the brightness of the
If there is a malfunction, “– –.–” will be con- speedometer, tachometer and
Brightness
tinuously displayed. Check the vehicle. the multi-function display panel
to suit the outside lighting con-
Setting mode ditions.
Clock
the clock.
1
This function allows you to
reset all items to factory preset
or default setting, except the
All Reset
odometer, clock, maintenance
counter item “Oil” and mainte-
nance counter item “V-Belt”.
TIP
• Using the select switch “ / ” to switch the
display items.
1. Setting mode display
• If grip warmer or seat heater is not equipped,
TIP the “Grip Warmer” or “Seat Heater” items will
• The vehicle must be stopped to change set- not appear.
tings in this mode.
Grip warmer settings
• Starting off or turning the vehicle power off
1. Use the select switch to highlight “Grip
saves all settings made, then exits the setting
Warmer”.
mode.
Push the “MENU” switch for 2 seconds to enter
the setting mode. To exit the setting mode and
1-16
FEATURES
2. Push the “MENU” switch. The grip warmer 2. Push the “MENU” switch. The seat heater
setting display will be shown and “High” will setting display will be shown and “High” will
flash in the display. flash in the display.
3. Push the “MENU” switch. The temperature 3. Push the “MENU” switch. The temperature
level for the high setting will start flashing. level for the high setting will start flashing.
Use the select switch to set the temperature Use the select switch to set the temperature
level, and then push the “MENU” switch. level, and then push the “MENU” switch.
“High” will start flashing. “High” will start flashing.
4. Use the select switch to highlight “Mid” or 4. Use the select switch to highlight “Mid” or
“Low”, and then change the setting using the “Low”, and then change the setting using the
same procedure that was used for the high same procedure that was used for the high
setting. setting.
5. When you finished changing the settings, use 5. When you finished changing the settings, use
the select switch to highlight “ ”, and then the select switch to highlight “ ”, and then
push the “MENU” switch to return to the set- push the “MENU” switch to return to the set-
ting mode menu. ting mode menu.
Seat heater settings Traction control system settings
1. Use the select switch to highlight “Seat Heat- 1. Use the select switch to highlight “Traction
er”. Control”.
1-17
FEATURES
2. Push the “MENU” switch. The traction control 2. Push the “MENU” switch, and then use the
system setting display will be shown and select switch to select the item to reset.
“ON” will flash in the display.
3. While the selected item is flashing, push the

3. To set the traction control system to “OFF”, select switch “ ” for one second.
push the select switch “ ” side for 2 sec-
onds.
4. When you finished resetting, use the select

switch to highlight “ ”, and then push the
4. To set the traction control system to “ON” “MENU” switch to return to the setting mode
again, push the select switch “ ” for at least menu.
one second. Selecting the units
TIP TIP
When the vehicle is powered on, the traction For the UK: This function does not indicate on
control system is set to “ON”. setting mode display and cannot be selected.
5. When you finished changing the settings, 1. Use the select switch to highlight “Unit”.
push the “MENU” switch to return to the set-
ting mode menu.
Resetting the maintenance counters
1. Use the select switch to highlight “Mainte-
nance”.
1-18
FEATURES
2. Push the “MENU” switch, use the select

switch to highlight the display to change, and
then push the “MENU” switch again.
2. Push the “MENU” switch. The unit setting dis-

play will be shown and “L/100km” will flash in
the display.
3. Use the select switch to highlight the item to
change, and then push the “MENU” switch.
3. Use the select switch to select “L/100km” or

“km/L”, and then push the “MENU” switch
again. TIP
Display item order is as follows.
A.TEMP TRIP-1 TRIP-2
ODO
CRNT.F F.AVG RANGE

4. Push the “MENU” switch to return to the set-
ting mode menu.
4. Use the select switch to select the item to
Selecting the display items
show, and then push the “MENU” switch.
1. Use the select switch to highlight “Display
Change”.
5. When you finished changing the settings, use

the select switch to highlight “ ”, and then
1-19
FEATURES
push the “MENU” switch to return to the pre-

vious display.
6. Use the select switch to highlight “ ”, and
then push the “MENU” switch to return to the
setting mode menu.
Meter panel brightness
1. Use the select switch to highlight “Bright-
ness”.
4. Push the “MENU” switch, and the minute dig-

its start flashing.
2. Push the “MENU” switch.

3. Use the select switch to select the desired
brightness level.
5. Use the select switch to set the minutes.

ting mode menu.
Resetting all of the display items
1. Use the select switch to highlight “All Reset”.

ting mode menu.
Setting the clock
TIP
The clock uses a 12-hour time system.
1. Use the select switch to highlight “Clock”.
3. Use the select switch to highlight “YES”, and
then push the “MENU” switch. All items are
reset to factory preset or default settings.

3. When the hour digits start flashing, use the
select switch to set the hours.
1-20
FEATURES
TIP
The odometer, clock, maintenance counter item
“Oil” and maintenance counter item “V-Belt” will
not be reset.
To exit the setting mode
1. Use the select switch to highlight “Return”.
2. Push the “MENU” switch to exit the setting

mode and return to the standard display
mode.
1-21
IMPORTANT INFORMATION
EAS20009
EAS30006
PREPARATION FOR REMOVAL AND

DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
EAS30008
GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
2. Use only the proper tools and cleaning equip- lips with grease.
ment.
Refer to “SPECIAL TOOLS” on page 1-29.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must
always be reused or replaced as an assem-
bly.
1. Oil
2. Lip
3. Spring
4. Grease
EAS30009
LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace all lock washers/plates
4. During disassembly, clean all of the parts and “1” and cotter pins. After the bolt or nut has been
place them in trays in the order of disassem- tightened to specification, bend the lock tabs
bly. This will speed up assembly and allow for along a flat of the bolt or nut.
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS30007
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
EAS30010
BEARINGS AND OIL SEALS

Install bearings “1” and oil seals “2” so that the
manufacturer marks or numbers are visible.
1-22
When installing oil seals, lubricate the oil seal contact the parts.
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
ECA13300
NOTICE
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
EAS30011
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
EAS30012
RUBBER PARTS
Check rubber parts for deterioration during in-
spection. Some of the rubber parts are sensitive
to gasoline, flammable oil, grease, etc. Do not al-
low any items other than the specified one to
1-23
BASIC SERVICE INFORMATION
EAS20010

EAS30013
QUICK FASTENERS
Rivet type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, push its pin with a
screwdriver, then pull the fastener out.
Screw type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.
2. Install:
• Quick fastener
TIP
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the part to be secured and push
the pin in with a screwdriver. Make sure that the 2. Install:
pin is flush with the fastener’s head. • Quick fastener
TIP
To install the quick fastener, insert the fastener
into the part to be secured and tighten the screw.
1-24
ECA16760
EAS30014
ELECTRICAL SYSTEM NOTICE

Electrical parts handling Be sure to connect the battery leads to the
ECA16600
correct battery terminals. Reversing the bat-
NOTICE tery lead connections could damage the
Never disconnect a battery lead while the en- electrical components.
gine is running; otherwise, the electrical
components could be damaged.
ECA16771
NOTICE
ECA16751
When connecting the battery leads to the
NOTICE battery, be sure to connect the positive bat-
When disconnecting the battery leads from tery lead first, then the negative battery lead.
the battery, be sure to disconnect the nega- If the negative battery lead is connected first
tive battery lead first, then the positive bat- and a tool or similar item contacts the vehi-
tery lead. If the positive battery lead is cle while the positive battery lead is being
disconnected first and a tool or similar item connected, a spark could be generated,
contacts the vehicle, a spark could be gener- which is extremely dangerous.
ated, which is extremely dangerous.
ECA25740
TIP NOTICE
If a battery lead is difficult to disconnect due to Push the OFF/LOCK switch before discon-
rust on the battery terminal, remove the rust us- necting or connecting an electrical compo-
ing hot water. nent.
1-25
ECA16620
Checking the electrical system
NOTICE
TIP
Handle electrical components with special Before checking the electrical system, make
care, and do not subject them to strong sure that the battery voltage is at least 12 V.
shocks.
ECA14371
ECA16630
NOTICE
NOTICE
Never insert the tester probes into the cou-
Electrical components are very sensitive to pler terminal slots. Always insert the probes
and can be damaged by static electricity. from the opposite end “a” of the coupler, tak-
Therefore, never touch the terminals and be ing care not to loosen or damage the leads.
sure to keep the contacts clean.
ECA16640
TIP NOTICE
When resetting the ECU by pushing the For waterproof couplers, never insert the
OFF/LOCK switch, be sure to wait approximate- tester probes directly into the coupler. When
ly 5 seconds before pushing the ON/start switch. performing any checks using a waterproof
coupler, use the specified test harness or a
suitable commercially available test har-
ness.
1-26
Checking the connections 2. Check:

Check the leads, couplers, and connectors for • Lead
stains, rust, moisture, etc. • Coupler
1. Disconnect: • Connector
• Lead Moisture  Dry with an air blower.
• Coupler Rust/stains  Connect and disconnect sev-
• Connector eral times.
ECA16780
NOTICE
• When disconnecting a coupler, release the
coupler lock, hold both sections of the cou-
pler securely, and then disconnect the cou-
pler.
• There are many types of coupler locks;
therefore, be sure to check the type of cou-
pler lock before disconnecting the coupler.
3. Connect:
• Lead
• Coupler
• Connector
TIP
• When connecting a coupler or connector, push
both sections of the coupler or connector to-
gether until they are connected securely.
• Make sure all connections are tight.
ECA16790
NOTICE
When disconnecting a connector, do not pull
the leads. Hold both sections of the connec-
tor securely, and then disconnect the con-
nector.
1-27
5. Check:
• Resistance
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with tachom-
eter
YU-A1927
TIP
The resistance values shown were obtained at
4. Check: the standard measuring temperature of 20 C
• Continuity (68 F). If the measuring temperature is not 20
(with the digital circuit tester) C (68 F), the specified measuring conditions
will be shown.
90890-03243
Model 88 Multimeter with tachom- Intake air temperature sensor re-
eter sistance
YU-A1927 5400–6600  at 0 C (5400–6600
 at 32 F)
TIP Intake air temperature sensor re-
• If there is no continuity, clean the terminals. sistance
289–391  at 80 C (289–391  at
• When checking the wire harness, perform
176 F)
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
1-28
SPECIAL TOOLS
EAS20012
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP
• For U.S.A. and Canada, use part numbers starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part numbers starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
Digital circuit tester (CD732) 1-28, 1-28, 5-32,

90890-03243 8-227, 8-228,
Model 88 Multimeter with tachometer 8-228, 8-229,
YU-A1927 8-233, 8-239,
8-240, 8-241,
8-241, 8-242,
8-242, 8-243,
8-244, 8-244,
8-245, 8-246,
8-246, 8-248,
8-248, 8-249,
8-249, 8-250,
8-250
Yamaha diagnostic tool USB 3-4, 3-13, 4-75,
90890-03256 4-77, 8-62,
8-171, 8-191
Yamaha diagnostic tool (A/I) 3-4, 3-13, 4-75,

90890-03254 4-77, 8-62,
8-171, 8-191
Valve lapper 90890-04101

3-7
90890-04101
Valve lapping tool
YM-A8998
YM-A8998
1-29
SPECIAL TOOLS
Reference
pages
Vacuum gauge 3-10

90890-03094
Vacuummate
YU-44456
YU-44456
Carburetor angle driver 2 3-10

90890-03173
Tension meter (TEXA) 3-22

90890-03258
Steering nut wrench 3-25, 4-98

90890-01403
Exhaust flange nut wrench
YU-A9472
Oil filter wrench 3-28, 6-6

90890-01426
Oil filter wrench
YU-38411
Oil pressure gauge set 3-30

90890-03120
Oil pressure adapter B 3-30

90890-03124
1-30
SPECIAL TOOLS
Tool name/Tool No. Illustration Reference

pages
Pressure gauge 3-30, 7-12, 7-12

90890-03153
Pressure gauge
YU-03153
Thickness gauge 4-30, 4-39, 5-16,

90890-03180 5-55
Feeler gauge set
YU-26900-9
Fork spring compressor 4-89, 4-94

90890-01441
Fork spring compressor
YM-01441
Rod holder 4-89, 4-94

90890-01434
Damper rod holder double ended
YM-01434
Damper rod holder (ø27) 4-90, 4-93

90890-01423
Damping rod holder
YM-01423
Fork seal driver 4-92, 4-92, 4-92

90890-01442
Adjustable fork seal driver (36–46 mm)
YM-01442
Rod puller 4-93

90890-01437
Universal damping rod bleeding tool set
YM-A8703
YM-A8703
1-31
SPECIAL TOOLS
Reference
pages
Rod puller attachment (M10) 4-93

90890-01436
Universal damping rod bleeding tool set
YM-A8703
YM-A8703
Compression gauge 90890-03081 5-1

90890-03081
Engine compression tester
YU-33223
YU-33223
Yamaha bond No. 1215 5-14, 5-41, 5-49,

90890-85505 5-65
(Three bond No.1215®)
Valve spring compressor 5-19, 5-24

90890-04019
Valve spring compressor
YM-04019
Valve spring compressor attachment 5-19, 5-24

90890-04114
Valve spring compressor adapter 19.5 mm
YM-04114
1-32
SPECIAL TOOLS
Reference
pages
Valve guide remover (ø4) 5-21

90890-04111
Valve guide remover (4.0 mm)
YM-04111
Valve guide installer (ø4) 5-21

90890-04112
Valve guide installer (4.0 mm)
YM-04112
Valve guide reamer (ø4) 5-21

90890-04113
Valve guide reamer (4.0 mm)
YM-04113
Piston pin puller set 5-26

90890-01304
Piston pin puller
YU-01304
YU-01304
Sheave holder 5-38, 5-38, 5-41,

90890-01481 5-42, 5-42
Locknut wrench 5-38, 5-38, 5-41

90890-01348
Locknut wrench
YM-01348
1-33
SPECIAL TOOLS
Reference
pages
Sheave spring compressor 5-38, 5-41

90890-04134
Sheave spring compressor
YM-04134
Sheave fixed block 5-38, 5-41

90890-04135
Sheave fixed bracket
YM-04135
Sheave holder 5-47, 5-47, 5-48,

90890-01701 5-49
Primary clutch holder
YS-01880-A
Flywheel puller 5-47

90890-01362
Heavy duty puller
YU-33270-B
Rotor holding tool 5-54, 5-58

90890-01235
Universal magneto and rotor holder
YU-01235
Clutch spring compressor 5-54, 5-57

90890-01482
1-34
SPECIAL TOOLS
Reference
pages
Universal clutch holder 5-54, 5-57

90890-04086
Universal clutch holder
YM-91042
Plane bearing installer 5-69, 5-73

90890-04139
Radiator cap tester 6-3, 6-3

90890-01325
Mityvac cooling system tester kit
YU-24460-A
YU-24460-A
Radiator cap tester adapter 6-3, 6-3

90890-01352
Pressure tester adapter
YU-33984
YU-33984
Mechanical seal installer 6-12

90890-04132
Water pump seal installer
YM-33221-A
1-35
SPECIAL TOOLS
Reference
pages
Middle driven shaft bearing driver 6-12

90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058
Fuel injector pressure adapter 7-12

90890-03210
Fuel injector pressure adapter
YU-03210
Fuel pressure adapter 7-12

90890-03186
Fuel pressure adapter
YM-03186
OBD/ GST Leadwire kit 8-62

90890-03249
Ignition checker 8-242

90890-06754
Oppama pet–4000 spark checker
YM-34487
Test harness– lean angle sensor (6P) 8-242

90890-03209
Test harness– lean angle sensor (6P)
YU-03209
Test harness S– pressure sensor (3P) 8-249

90890-03207
Test harness S– pressure sensor (3P)
YU-03207
1-36
SPECIAL TOOLS
1-37
SPECIFICATIONS
GENERAL SPECIFICATIONS..........................................................................2-1
ENGINE SPECIFICATIONS .............................................................................2-2

1
CHASSIS SPECIFICATIONS ...........................................................................2-7
ELECTRICAL SPECIFICATIONS ..................................................................2-10

2
TIGHTENING TORQUES ...............................................................................2-12
GENERAL TIGHTENING TORQUE SPECIFICATIONS..........................2-12
3
ENGINE TIGHTENING TORQUES..........................................................2-13
CHASSIS TIGHTENING TORQUES........................................................2-13
LUBRICATION POINTS AND LUBRICANT TYPES......................................2-15

ENGINE....................................................................................................2-15
4
CHASSIS..................................................................................................2-16
LUBRICATION SYSTEM CHART AND DIAGRAMS .....................................2-19

ENGINE OIL LUBRICATION CHART ......................................................2-19
LUBRICATION DIAGRAMS .....................................................................2-21
COOLING SYSTEM DIAGRAMS ...................................................................2-29 5

CABLE ROUTING ..........................................................................................2-33
6
7
8
9
GENERAL SPECIFICATIONS
EAS20013
GENERAL SPECIFICATIONS
Model
Model BC31 (XP530D-A)
BV11 (XP530E-A)
BX31 (XP530-A)
Dimensions
Overall length 2200 mm (86.6 in)
Overall width 765 mm (30.1 in)
Overall height 1420/1475 mm (55.9/58.1 in) (XP530-A,
XP530E-A)
1420/1555 mm (55.9/61.2 in) (XP530D-A)
Wheelbase 1575 mm (62.0 in)
Ground clearance 125 mm (4.92 in)
Minimum turning radius 2.8 m (9.19 ft)
Weight
Curb weight 213 kg (470 lb) (XP530-A, XP530E-A)
216 kg (476 lb) (XP530D-A)
Loading
Maximum load 199 kg (439 lb) (XP530D-A)
202 kg (445 lb) (XP530-A, XP530E-A)
Riding capacity 2 person
2-1
ENGINE SPECIFICATIONS
EAS20014
Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train DOHC
Displacement 530 cm³
Cylinder arrangement Inline
Number of cylinders 2-cylinder
Bore  stroke 68.0  73.0 mm (2.68  2.87 in)
Compression ratio 10.9 : 1
Compression pressure 1696–2184 kPa/470 r/min (17.0–21.8
kgf/cm²/470 r/min, 241.3–310.6 psi/470 r/min)
Starting system Electric starter
Fuel
Recommended fuel Regular unleaded gasoline (Gasohol [E10] ac-
ceptable)
Fuel tank capacity 15 L (4.0 US gal, 3.3 Imp.gal)
Fuel reserve amount 3.0 L (0.79 US gal, 0.66 Imp.gal)
Engine oil
Recommended brand YAMALUBE
SAE viscosity grades 10W-40
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Lubrication system Dry sump
Engine oil quantity
Oil change 2.60 L (2.75 US qt, 2.29 Imp.qt)
With oil filter removal 2.90 L (3.07 US qt, 2.55 Imp.qt)
Quantity (disassembled) 3.50 L (3.70 US qt, 3.08 Imp.qt)
Oil filter
Oil filter type Cartridge
Oil pump
Oil pressure 120.0 kPa/1200 r/min (1.20 kgf/cm²/1200 r/min,
17.4 psi/1200 r/min)
Relief valve operating pressure 450.0–550.0 kPa (4.50–5.50 kgf/cm², 65.3–79.8
psi)
Cooling system
Coolant quantity
Radiator (including all routes) 1.67 L (1.77 US qt, 1.47 Imp.qt)
Coolant reservoir (up to the maximum level 0.25 L (0.26 US qt, 0.22 Imp.qt)
mark)
Radiator cap valve opening pressure 107.9–137.3 kPa (1.08–1.37 kgf/cm², 15.6–19.9
psi)
Thermostat
Valve opening temperature 69.0–73.0 C (156.20–163.40 F)
Valve full open temperature 85.0 C (185.00 F)
Valve lift (full open) 8.0 mm (0.31 in)
Water pump
Water pump type Single suction centrifugal pump
Impeller shaft tilt limit 0.15 mm (0.006 in)
2-2
Spark plug(s)
Manufacturer/model NGK/CR7E
Spark plug gap 0.7–0.8 mm (0.028–0.031 in)
Cylinder head
Warpage limit 0.03 mm (0.0012 in)
Camshaft
Camshaft cap inside diameter 23.000–23.021 mm (0.9055–0.9063 in)
Camshaft journal diameter 22.959–22.972 mm (0.9039–0.9044 in)
Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in)
Limit 0.080 mm (0.0032 in)
Camshaft lobe dimensions
Lobe height (Intake) 32.490–32.590 mm (1.2791–1.2831 in)
Limit 32.390 mm (1.2752 in)
Lobe height (Exhaust) 32.690–32.790 mm (1.2870–1.2909 in)
Limit 32.590 mm (1.2831 in)
Camshaft runout limit 0.030 mm (0.0012 in)
Valve, valve seat, valve guide
Valve clearance (cold)
Intake 0.15–0.22 mm (0.0059–0.0087 in)
Exhaust 0.25–0.32 mm (0.0098–0.0126 in)
Valve dimensions
Valve seat contact width (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Limit 1.6 mm (0.06 in)
Valve seat contact width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
Valve stem diameter (intake) 3.975–3.990 mm (0.1565–0.1571 in)
Limit 3.945 mm (0.1553 in)
Valve stem diameter (exhaust) 3.960–3.975 mm (0.1559–0.1565 in)
Limit 3.930 mm (0.1547 in)
Valve guide inside diameter (intake) 4.000–4.012 mm (0.1575–0.1580 in)
Valve guide inside diameter (exhaust) 4.000–4.012 mm (0.1575–0.1580 in)
Valve-stem-to-valve-guide clearance (in- 0.010–0.037 mm (0.0004–0.0015 in)
take)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (ex- 0.025–0.052 mm (0.0010–0.0020 in)
haust)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.040 mm (0.0016 in)
Valve spring
Free length (intake) 36.73 mm (1.45 in)
Limit 34.89 mm (1.37 in)
Free length (exhaust) 36.73 mm (1.45 in)
Limit 34.89 mm (1.37 in)
Spring tilt (intake) 1.6 mm (0.06 in)
Spring tilt (exhaust) 1.6 mm (0.06 in)
Cylinder
Bore 68.000–68.010 mm (2.6772–2.6776 in)
Wear limit 68.060 mm (2.6795 in)
2-3
Piston
Diameter 67.975–67.990 mm (2.6762–2.6768 in)
Measuring point (from piston skirt bottom) 9.0 mm (0.35 in)
Piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in)
Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in)
Limit 16.043 mm (0.6316 in)
Piston pin outside diameter 15.995–16.000 mm (0.6297–0.6299 in)
Limit 15.975 mm (0.6289 in)
Piston-pin-to-piston-pin-bore clearance 0.002–0.018 mm (0.0001–0.0007 in)
Piston ring
Top ring
Ring type Barrel
End gap limit 0.60 mm (0.0236 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Side clearance limit 0.115 mm (0.0045 in)
2nd ring
Ring type Taper
End gap limit 0.85 mm (0.0335 in)
Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in)
Side clearance limit 0.115 mm (0.0045 in)
Connecting rod
Oil clearance 0.036–0.060 mm (0.0014–0.0024 in)
Bearing color code
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Crankshaft
Runout limit 0.030 mm (0.0012 in)
Crankshaft journal diameter 54.984-55.000 mm (2.1647-2.1654 in)
Journal oil clearance 0.040–0.087 mm (0.0016–0.0034 in)
Bearing color code
Code 0 White
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Code 5 Yellow
Balancer
Oil clearance 0.036–0.060 mm (0.0014–0.0024 in)
Bearing color code
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Clutch
Clutch type Wet, centrifugal, multiple-disc
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in)
Wear limit 2.82 mm (0.111 in)
Plate quantity 6 pcs
2-4
Clutch plate 1 thickness 1.30–1.50 mm (0.051–0.059 in)

Clutch plate 2 thickness 1.80–2.00 mm (0.071–0.079 in)
Clutch spring free length 31.90 mm (1.26 in)
Limit 24.80 mm (0.98 in)
Spring quantity 6 pcs
Clutch damper spring height 3.50 mm (0.14 in)
Minimum height 3.10 mm (0.12 in)
Clutch spring plate height 4.70 mm (0.19 in)
Minimum height 4.40 mm (0.17 in)
Clutch-in revolution 1650–2250 r/min
Clutch-stall revolution 3800–4800 r/min
V-belt
V-belt width 32.9 mm (1.30 in)
Limit 31.4 mm (1.24 in)
Drivetrain
Primary reduction ratio 1.000
Transmission type V-belt automatic
Transmission ratio 2.041–0.758 : 1
Weight outside diameter 25.0 mm (0.98 in)
Limit 24.5 mm (0.96 in)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Secondary shaft runout limit 0.12 mm (0.0047 in)
Secondary reduction ratio 6.034 (52/32 x 36/22 x 59/26)
Final drive Belt
Air filter
Air filter element Oil-coated paper element
V-belt filter element Dry element
Fuel pump
Pump type Electrical
Maximum consumption amperage 1.7 A
Fuel injector
Resistance 12.0 
Throttle body
ID mark BC31 00
Throttle position sensor
Resistance 1.20–2.80 k
Accelerator position sensor
Idling condition
Engine idling speed 1100–1300 r/min
O2 feedback control Active
Exhaust gas sampling point Muffler tail pipe
2-5
Engine oil temperature 60–80 C (140–176 F)

Intake vacuum 32.0 kPa (240 mmHg, 9.4 inHg)
Difference in vacuum pressure between the 0 kPa–1.3 kPa (0 mmHg–10 mmHg, 0 inHg–0.4
cylinders inHg)
CO% 0.0–2.0 %
Fuel line pressure (at idle) 220–300 kPa (2.2–3.0 kgf/cm², 31.9–43.5 psi)
Throttle grip free play 1.0–3.0 mm (0.04–0.12 in)
2-6
CHASSIS SPECIFICATIONS
EAS20015
Chassis
Frame type Diamond
Caster angle 26.0 
Trail 98 mm (3.9 in)
Front wheel
Wheel type Cast wheel
Rim size 15M/C x MT3.5
Rim material Aluminum
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Rear wheel
Wheel type Cast wheel
Rim size 15M/C x MT4.5
Rim material Aluminum
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Front tire
Type Tubeless
Size 120/70R15M/C(56H)
Manufacturer/model BRIDGESTONE/BATTLAXSCF (XP530-A,
XP530E-A)
DUNLOP/ROADSMART3 (XP530D-A)
Rear tire
Type Tubeless
Size 160/60R15M/C(67H)
Manufacturer/model BRIDGESTONE/BATTLAXSCR (XP530-A,
XP530E-A)
DUNLOP/ROADSMART3 (XP530D-A)
Tire air pressure (measured on cold tires)
1 person
Front 225 kPa (2.25 kgf/cm², 33 psi)
Rear 250 kPa (2.50 kgf/cm², 36 psi)
2 persons
Front 225 kPa (2.25 kgf/cm², 33 psi)
Rear 280 kPa (2.80 kgf/cm², 41 psi)
Front brake
Type Hydraulic dual disc brake
Disc outside diameter  thickness 267.0  4.0 mm (10.51  0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc runout limit (as measured on 0.15 mm (0.0059 in)
wheel)
Brake pad lining thickness 4.0 mm (0.16 in)
Master cylinder inside diameter 15.00 mm (0.59 in)
Caliper cylinder inside diameter (Left) 30.23 mm, 27.00 mm (1.19 in, 1.06 in)
Caliper cylinder inside diameter (Right) 30.23 mm, 27.00 mm (1.19 in, 1.06 in)
Specified brake fluid DOT 4
2-7
Rear brake
Type Hydraulic single disc brake
Disc outside diameter  thickness 282.0  5.0 mm (11.10  0.20 in)
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc runout limit (as measured on 0.15 mm (0.0059 in)
wheel)
Master cylinder inside diameter 14.0 mm (0.55 in)
Caliper cylinder inside diameter 38.10 mm (1.50 in)
Specified brake fluid DOT 4
Rear brake lock
Rear brake lock pad
Front suspension
Type Telescopic fork
Spring Coil spring
Shock absorber Hydraulic damper
Wheel travel 120 mm (4.7 in)
Fork spring free length 297.1 mm (11.70 in)
Limit 291.1 mm (11.46 in)
Inner tube bending limit 0.2 mm (0.01 in)
Recommended oil Yamaha Suspension Oil 01
Quantity (left) 447.0 cm³ (15.11 US oz, 15.77 Imp.oz)
Quantity (right) 437.0 cm³ (14.77 US oz, 15.41 Imp.oz)
Level (left) 114 mm (4.5 in)
Level (right) 118 mm (4.6 in)
Rear suspension
Type Swingarm (link suspension)
Spring Coil spring
Shock absorber Gas-hydraulic damper
Wheel travel 117 mm (4.6 in)
Spring preload
Adjusting system Mechanical adjustable type (XP530D-A)
Unit for adjustment Cam position (XP530D-A)
Adjustment value (Soft) 7 (XP530D-A)
Adjustment value (STD) 4 (XP530D-A)
Adjustment value (Hard) 1 (XP530D-A)
Rebound damping
Adjusting system Mechanical adjustable type (XP530D-A)
Unit for adjustment Turn (XP530D-A)
Adjustment value from the start position 3 (XP530D-A)
(Soft)
Adjustment value from the start position 1.25 (XP530D-A)
(STD)
Adjustment value from the start position 0 (XP530D-A)
(Hard)
2-8
Drive belt
Drive belt vibration frequency 74–94 Hz
2-9
ELECTRICAL SPECIFICATIONS
EAS20016
Voltage
System voltage 12 V
Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 5.0 1200 r/min
Engine control unit
Model TBDF0H (XP530-A)
TBDF0K (XP530E-A)
TBDFT6 (XP530D-A)
Ignition coil
Primary coil resistance 1.87–2.53 
Secondary coil resistance 12.00–18.00 k
Spark plug cap
Lean angle sensor output voltage
Operating angle 65 
Output voltage up to operating angle 0.4–1.4 V
Output voltage over operating angle 3.7–4.4 V
Charging system
Charging system AC magneto
Standard output 14.0 V, 25.0 A at 5000 r/min
Standard output 14.0 V, 350 W at 5000 r/min
Stator coil resistance 0.224–0.336 
Rectifier/regulator
Regulator type Three-phase
Regulated voltage (DC) 14.1–14.9 V
Rectifier capacity (DC) 25.0 A
Battery
Model YTZ12S
Voltage, capacity 12 V, 11.0 Ah (10 HR)
Bulb wattage
Headlight LED
Brake/tail light LED
Front turn signal light 21.0 W
Rear turn signal light LED
Auxiliary light LED
License plate light 5.0 W
Meter lighting LED
Indicator light
High beam indicator light LED
Turn signal indicator light LED
Engine trouble warning light LED
ABS warning light LED
Cruise control “SET” indicator light LED (XP530D-A)
Cruise control “ON” indicator light LED (XP530D-A)
2-10
Smart key system indicator light LED

Traction control system indicator/warning light LED
Starter motor
Power output 0.70 kW
Armature coil resistance 0.0105–0.0195 
Brush overall length 12.0 mm (0.47 in)
Limit 6.50 mm (0.26 in)
Brush spring force 6.02–6.51 N (614–664 gf, 21.69–23.45 oz)
Mica undercut (depth) 0.70 mm (0.03 in)
Fuel sender unit
Sender unit resistance (full) 10.0–14.0 
Sender unit resistance (empty) 267.0–273.0 
Grip warmer
Grip warmer resistance (L) 1.2–1.4  (XP530D-A)
Grip warmer resistance (R) 1.2–1.5  (XP530D-A)
Seat heater resistance 8.8–10.8  (XP530D-A)
Fuel injection sensor
Crankshaft position sensor resistance 228–342 
Intake air temperature sensor resistance 5400–6600  at 0 C (5400–6600  at 32 F)
Intake air temperature sensor resistance 289–391  at 80 C (289–391  at 176 F)
Coolant temperature sensor resistance 2512–2777  at 20 C (2512–2777  at 68 F)
Coolant temperature sensor resistance 210–220  at 100 C (210–220  at 212 F)
Fuse(s)
Main fuse 40.0 A
Headlight fuse 7.5 A
Taillight fuse 7.5 A
Brake light fuse 1.0 A (XP530D-A)
Signaling system fuse 7.5 A
Ignition fuse 7.5 A
Radiator fan motor fuse 15.0 A
Fuel injection system fuse 7.5 A
ABS control unit fuse 7.5 A
ABS motor fuse 30.0 A
ABS solenoid fuse 15.0 A
Cruise control fuse 1.0 A (XP530D-A)
Auxiliary DC jack fuse 2.0 A
Backup fuse 15.0 A
Windshield motor fuse 20.0 A (XP530D-A)
Electronic throttle valve fuse 7.5 A
Seat lock fuse 7.5 A (XP530-A, XP530E-A)
2-11
TIGHTENING TORQUES
EAS20017
TIGHTENING TORQUES
EAS30015
GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special com-
ponents or assemblies are provided for each
chapter of this manual. To avoid warpage, tight-
en multi-fastener assemblies in a crisscross pat-
tern and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications re-
quire clean, dry threads. Components should be
at room temperature.
A. Distance between flats

B. Outside thread diameter
General tightening torques

A (nut) B (bolt)
N·m kgf·m lb·ft
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2-12
TIGHTENING TORQUES
EAS30016
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Exhaust pipe nut M8 4 20 N·m (2.0 kgf·m, 15 lb·ft)

Muffler protector bolt M6 3 8 N·m (0.8 kgf·m, 5.9 lb·ft) LT
Front muffler protector bolt M6 3 7 N·m (0.7 kgf·m, 5.2 lb·ft) LT
Spark plug M10 2 13 N·m (1.3 kgf·m, 9.6 lb·ft)

Cylinder head cover bolt M6 10 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Generator rotor nut M18 1 See TIP. E
Generator cover bolt M6 19 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Clutch assembly nut M16 1 65 N·m (6.5 kgf·m, 48 lb·ft)
Oil filter cartridge M20 1 17 N·m (1.7 kgf·m, 13 lb·ft)
Oil filter cartridge union bolt M20 1 40 N·m (4.0 kgf·m, 30 lb·ft) E
Coolant drain bolt M12 1 1.6 N·m (0.16 kgf·m, 1.2 lb·ft)
Engine oil drain bolt M14 1 43 N·m (4.3 kgf·m, 32 lb·ft)
TIP
Generator rotor nut
Tighten the generator rotor nut to 65 N·m (6.5 kgf·m, 48 lb·ft), and then tighten them further to reach the
specified angle 120.
EAS30017
CHASSIS TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Front wheel axle M14 1 91 N·m (9.1 kgf·m, 67 lb·ft)

Front wheel axle pinch bolt M8 4 21 N·m (2.1 kgf·m, 15 lb·ft) See TIP.
Rear wheel pulley bolt M10 5 64 N·m (6.4 kgf·m, 47 lb·ft) LT
Rear wheel axle nut M24 1 160 N·m (16 kgf·m, 118 lb·ft)
Rear brake caliper bolt M10 2 27 N·m (2.7 kgf·m, 20 lb·ft) S
Front brake caliper bleed screw M8 2 5 N·m (0.5 kgf·m, 3.7 lb·ft)
Rear brake caliper bleed screw M7 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Front brake caliper bolt M10 4 35 N·m (3.5 kgf·m, 26 lb·ft)
Upper handlebar holder bolt M8 4 23 N·m (2.3 kgf·m, 17 lb·ft)
Lower handlebar holder nut M10 2 34 N·m (3.4 kgf·m, 25 lb·ft)
Lower bracket pinch bolt M8 4 23 N·m (2.3 kgf·m, 17 lb·ft)
Upper bracket pinch bolt M8 2 30 N·m (3.0 kgf·m, 22 lb·ft)
Lower ring nut M30 1 See TIP.
Drive pulley assembly bolt M10 5 48 N·m (4.8 kgf·m, 35 lb·ft)
2-13
TIGHTENING TORQUES
TIP
Front wheel axle pinch bolt
1. Insert the front wheel axle from the right side, temporarily install the front wheel axle bolt “1” from the
left side, and then tighten the front wheel axle to 91 N·m (9.1 kgf·m, 67 lb·ft).
2. Tighten the pinch bolt “3”, pinch bolt “2”, and pinch bolt “3” to 21 N·m (2.1 kgf·m, 15 lb·ft) in this order.
3. Check that the right end of the front axle is flush with the front fork. If necessary, manually push the
front axle or lightly tap it with a soft hammer until its end is flush with the front fork. However, if the
surface of the front axle end is not parallel to the surface of the front fork, align a point on the outer
edge of the axle with the fork, making sure that the axle does not protrude past the fork.
4. Tighten the pinch bolt “5”, pinch bolt “4”, and pinch bolt “5” to 21 N·m (2.1 kgf·m, 15 lb·ft) in this order.
5 4 3 2
TIP
Lower ring nut
1. Tighten the ring nut to 52 N·m (5.2 kgf·m, 38 lb·ft) with a torque wrench, then loosen the lower ring
nut completely.
2. Tighten the lower ring nut to 16 N·m (1.6 kgf·m, 12 lb·ft).
2-14
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20018

EAS30018
ENGINE
Lubrication point Lubricant
Oil seal lips LS
O-rings LS
Coolant hose insertion part Water or S
Bearings and bushings E
Cylinder head nut seats and washers E
Camshaft cap bolt seats E
Crankshaft big ends E
Piston surfaces E
Piston pins E
Crankshaft journals E
Balancer piston surface E
Balancer piston pin E
Generator rotor nut E
Camshaft lobes and journals (intake and exhaust) M
Valve stem seals (intake and exhaust) S
Valve stems and stem ends (intake and exhaust) M
Valve lifter outer surface (intake and exhaust) E
Water pump impeller shaft M
O-ring (coolant pipe) LS or S
Oil pump shaft and rotors (inner and outer) E
Oil pump gaskets LS
V-belt case air filter case screw bushing Water or S
V-belt case air filter case cover screw bushing Water or S
Crankshaft end access cover screw bushing Water or S
Generator cover protector screw bushing Water or S
Starter clutch idle gear shaft E
Starter clutch idle gear ends E
Starter clutch and starter clutch gear E
Starter clutch gear ends E
Washer (starter clutch gear) E
Starter clutch gear inner surface and crankshaft E
2-15
Primary driven gear spline and main axle spline E or LS
1st pinion gear spline and main axle spline E or LS
1st wheel gear spline and drive axle spline E or LS
Swingarm (left) taper roller bearing LS
YAMAHA GREASE “G”

Primary sheave spacer and o-ring (Shell Sunlight Grease
3®)
YAMAHA GREASE “G”
Primary sheave nut (Shell Sunlight Grease
3®)
YAMAHA GREASE “H”
Secondary sheave nut
(Polyurea Grease®)
Secondary shaft right end bearing LS
Pivot shaft taper roller bearing LS
Yamaha bond No. 1215

Stopper (generator cover and water pump assembly)
Crankcase mating surface (Three bond No.1215®)
Inner V-belt case seal mating surface (Three bond No.1215®)
Crankshaft position sensor/stator lead grommet
EAS30019
CHASSIS
Steering bearings (upper and lower) LS
Upper bearing cover seal lip and lower bearing dust seal lip LS
Tube guide (throttle grip) inner surface and throttle cables LS
Moving parts of the grip warmer lead and the inside of the handlebar switch (right) LS
(for XP530D-A)
Rear brake lock cable end (lever end) YAMAHA GREASE “F”
Brake lever pivoting point and metal-to-metal moving parts S
YAMAHA GREASE “J”

Drive axle spline (Shell Alvania EP
Grease R0®)
YAMAHA GREASE “J”
Drive pulley assembly pivoting point (Shell Alvania EP
Grease R0®)
Collar outer surface (relay arm, connecting arm) LS
Pivot shaft oil seal and collar LS
Seat lock metal-to-metal moving parts LS
Seat hinge metal-to-metal moving parts LS
2-16
Passenger footrest pivoting point LS
Centerstand pivoting point and metal-to-metal moving parts LS
Centerstand hook and spring contact point LS
Sidestand pivoting point and metal-to-metal moving parts LS
Sidestand hook and spring contact point LS
Front wheel oil seal lip LS
Rear wheel oil seal lip LS
Front wheel axle bolt mating surface LS
Brake caliper piston seal

Master cylinder inside
Brake caliper piston dust seal S
Rear brake caliper bolts S
Rear brake lock caliper (caliper piston assembly (shaft L, piston adjusting bolt)) S
Rear brake lock caliper (slide pin bolt, sleeve) S
2-17
2-18
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20019

EAS30020
ENGINE OIL LUBRICATION CHART
2-19
1. Intake camshaft
2. Exhaust camshaft
3. Timing chain tensioner
4. Connecting rod
5. To piston
6. Starter clutch gear
7. Crankshaft
8. Balancer connecting rod
9. To balancer piston
10.Oil pipe
11.Check valve
12.Relief valve
13.Oil filter
14.Oil cooler
15.Oil tank
16.Oil strainer
17.Feed pump
18.Delivery pipe
19.Scavenge pump
20.Oil strainer
21.To starter idle gear
22.Clutch
23.Secondary shaft
24.To transmission
2-20
EAS30021
LUBRICATION DIAGRAMS
2-21
1. Exhaust camshaft
2. Intake camshaft
3. Delivery pipe
4. Oil pump assembly
5. Scavenge pump
6. Feed pump
7. Oil pipe
8. Oil cooler
9. Oil filter
10.Relief valve
11.Check valve
2-22
2-23
1. Crankshaft
2. Secondary shaft
3. Drive axle
4. Clutch
5. Generator cover
2-24
2-25
1. Oil strainer
2. Intake camshaft
3. Exhaust camshaft
2-26
2-27
1. Generator cover
2. Oil strainer
3. Main gallery
4. Crankcase (right)
A. Forward
2-28
COOLING SYSTEM DIAGRAMS
EAS20020
2-29
1. Radiator cap
2. Radiator filler hose
3. Cooling system air bleed hose
4. Coolant reservoir hose
5. Coolant pipe
6. Oil cooler outlet hose
7. Thermostat
8. Oil cooler
9. Oil cooler inlet hose
10.Coolant hose
11.Water pump outlet pipe
12.Radiator outlet hose
13.Radiator bracket
14.Coolant reservoir
15.Coolant reservoir breather hose
16.Radiator
17.Water pump
18.Water pump inlet pipe
2-30
2-31
1. Thermostat
2. Cooling system air bleed hose
4. Radiator cap
6. Radiator
7. Radiator bracket
8. Coolant pipe
9. Oil cooler
10.Oil cooler outlet hose
2-32
CABLE ROUTING
EAS20021
CABLE ROUTING
Headlight stay (front view)
2-33
CABLE ROUTING
1. Handlebar switch coupler 1 (left) (black)

2. Front brake light switch coupler (black) (for
XP530D-A)
3. Rear brake light switch coupler (white) (for
XP530D-A)
4. Handlebar switch coupler 2 (right) (white)
5. Handlebar switch lead (left/right)/Grip warmer
lead (left/right) (for XP530D-A)/Front brake
light switch lead (for XP530D-A)/Rear brake
light switch lead (for XP530D-A)
6. Wire harness (accelerator position sensor
lead)
7. Positive battery lead
8. Headlight stay
9. Plastic locking tie
10.Wire harness
11.Handlebar switch coupler (right) (white)
12.Handlebar switch coupler (left) (white)
13.Electrical components tray
14.Handlebar switch lead (left/right)/Grip warmer
A. Arrange the front wheel sensor coupler in

front of the wire harness.
B. Lead going to meter assembly
C. To front wheel sensor
D. Handlebar switch coupler 1 (left) (black), han-
dlebar switch coupler 1 (right) (white), han-
dlebar switch coupler 2 (right) (white),
handlebar switch coupler 3 (left) (white), rear
brake light switch coupler (white) (for
XP530D-A), front brake light switch coupler
(black) (for XP530D-A), handlebar switch
coupler 3 (right) (black) (except for XP530D-
A), handlebar switch coupler 4 (left) (white)
(except for XP530D-A)
The order of arrangement of the coupler
above does not matter.
E. Route the end of the positive battery lead
(before the taped section at the bottom) so
that it does not go between the wire harness
and the headlight stay.
F. Install the clamp to the headlight stay.
G. Fasten the headlight stay and the white tape
section of the wire harness with the plastic
locking tie. The end of the plastic locking tie
should face upward without being cut.
H. Route the handlebar switch lead (left/right) on
the inside of the windshield drive unit cable.
I. Install the coupler to the electrical compo-
nents tray.
J. Pass the plastic locking tie through the hole
of the electrical components tray and fasten
the white tape section of the lead. The end of
the plastic locking tie should face downward
without being cut.
2-34
CABLE ROUTING
Front cowling assembly (rear view)
2-35
CABLE ROUTING
1. Headlight control unit

2. Clamp
3. Front turn signal light coupler
4. Headlight assembly lead
5. Headlight sub-wire harness
A. Route the headlight sub-wire harness so that

the blue tape section is aligned with the rib
section of the headlight assembly.
B. Connect the headlight sub-wire harness cou-
pler to the coupler of the wire harness after
assembling the headlight assembly.
C. Fasten the headlight sub-wire harness and
headlight assembly lead with the clamp
between the right cover and the headlight
assembly mounting boss (within the range
shown in the illustration). The direction of the
clamp does not matter.
D. Route the headlight sub-wire harness (going
to the right turn signal light) in front of the
headlight assembly lead.
E. Fully push in the blue tape section of the
headlight sub-wire harness all the way to the
back of the rib section of the headlight
assembly.
F. Install the green tape section of the headlight
sub-wire harness to the rib section of the
headlight assembly.
G. Install the white tape section of the headlight
sub-wire harness to the rib section of the
headlight assembly.
H. Route the headlight sub-wire harness (going
to the left turn signal light) in front of the
headlight assembly lead. The number of
headlight assembly leads passing behind the
headlight sub-wire harness does not matter.
I. 3 locations
J. Push in the lead all the way to the back of the
rib.
K. The lead should enter on the inside of this
line.
L. Left and right 2 locations
2-36
CABLE ROUTING
Frame (right side view)
2-37
CABLE ROUTING
1. Storage compartment lid lock solenoid cou- Q. Front of the vehicle

pler (except for XP530E-A) R. Range of arrangement of the end of the plas-
2. Remote control unit lead tic locking tie
3. Grip warmer coupler (right) (gray) S. Left side of the vehicle
4. Auxiliary DC jack coupler (black) T. Fasten the white tape section of the horn lead
5. Grip warmer coupler (left) (black) and grommet of the brake hose with the plas-
tic locking tie. The end of the plastic locking
6. Windshield drive unit lead tie should face downward without being cut.
7. Leg shield U. Install the wire harness clamp into the hole in
8. Horn lead the front fuel tank bracket.
9. Coolant pipe
10.Radiator fan motor lead
11.Throttle position sensor lead
12.Windshield drive unit cable
13.Wire harness (To handlebar switch)
14.Wire harness (To remote control unit)
15.Front brake light switch lead/Rear brake light
switch lead (for XP530D-A)
16.Grip warmer lead (for XP530D-A)
17.Plastic locking tie
18.Brake hose
19.Rear brake lock cable
A. Route the remote control unit lead on the

inside of the brake hose.
B. Route the brake hose on the outside of all the
leads.
C. Install the wire harness clamp into the hole in
the electrical components tray.
D. Route the auxiliary DC jack lead on the inside
of the brake hose.
E. Route the radiator fan motor lead on the
inside of the coolant pipe.
F. Fasten the radiator fan motor lead with the
clamp and install it into the hole in the radia-
tor bracket.
G. Route the wire harness on the inside of the
brake hose.
H. Install the radiator fan motor coupler (wire
harness side) into the hole in the stay.
I. Route the horn lead on the outside of the
brake hose and rear brake lock cable.
J. Install the wire harness clamp into the hole in
the stay.
K. Install the clamp of the steering lock unit lead
into the hole in the stay.
L. Route the rear brake lock cable between the
frame and the wire harness.
M. Route the rear brake lock cable between the
frame and the brake hose.
N. Route the rectifier/regulator lead between the
wire harness and the electrical components
tray.
O. Number of leads going to the handlebar
switch (XP530E-A/XP530-A: 6, XP530D-A:
4)
P. Do not fasten the bare wire and coupler
directly with the plastic locking tie. The end of
the plastic locking tie should face toward the
left from the front.
2-38
CABLE ROUTING
2-39
CABLE ROUTING
1. Tail/brake light lead (right)

2. Storage box light switch lead
3. Rear wheel sensor lead
4. Fuel pump lead
5. O2 sensor lead
6. Storage box light lead
7. Storage box
8. Starter motor lead
9. Rear brake lock cable
10.Brake hose
11.Wire harness
A. Install the white tape section of the wire har-

ness into the notch area of the storage box.
After the wire harness is connected to the
tail/brake light lead and storage box light
switch lead, it is allowed to be detached from
the notch area.
B. Route the fuel pump lead under the rear
frame.
C. Coupler for the battery charger (optional)
D. Install the clamp of the O2 sensor lead into
the hole of the V-belt case air filter case.
E. To seat lock key cylinder
F. To seat heater (for XP530D-A)
G. Fasten the lead with the clamp.
H. It does not matter whether the storage box
light leads are installed on the left or right of
the storage box light.
I. Install the clamp of the seat heater lead
against the rib of the storage box.
J. Rib of storage box
K. Around the starter motor
L. Push in the starter motor lead underneath the
air duct.
M. Install the clamp within the range shown in
the illustration.
N. Install the O2 sensor coupler to the rear brake
lock cable bracket.
O. Fully insert the clamp all the way to the back
of the rear frame rib.
P. Fasten the O2 sensor lead to the rib section
of the V-belt case air filter case.
2-40
CABLE ROUTING
Frame (left side view)
2-41
CABLE ROUTING
1. Buzzer lead L. The front and back arrangement of the three

2. Intake air temperature sensor lead leads does not matter.
3. Yamaha diagnostic tool coupler M. Route the ground lead between the frame
and wire harness.
4. Negative battery lead
N. Install the ground lead with the caulked sec-
5. Headlight relay (dimmer) tion facing the inside.
6. Brake light relay (for XP530D-A) O. Fasten the frame, wire harness and starter
7. ECU lead 1 motor lead with the plastic locking tie at the
8. ECU lead 2 white tape section of the wire harness. The
end of the plastic locking tie should face
9. Throttle servo motor lead downward without being cut.
10.Clamp P. Fasten the wire harness with the plastic lock-
11.Spark plug lead (#2) ing tie after routing it on top of the front bolt
12.Spark plug lead (#1) securing the fuel tank bracket.
13.Fuel injection system relay
14.Steering lock relay
15.Starting circuit cut-off relay
16.Ignition coil lead 2 (orange)
17.Ignition coil lead 1 (red/black)
18.Ignition system relay
19.Smart key system relay (lock)
20.Smart key system relay (unlock)
21.Positive battery lead
22.Ground lead
23.Starter motor lead
24.Battery box
25.Frame
26.Ground lead (wire harness)
27.Wire harness
28.Joint connector lead
30.Fuel tank bracket
A. Install the buzzer to the ribs of the battery box

with the lead exit facing the bottom.
B. Push in the negative battery lead between
the battery box and wire harness after con-
necting it to the negative battery lead coupler.
C. To injector #1
D. Install the clamp of the throttle servo motor
lead into the hole in the motor cover.
E. Make sure the spark plug leads after this
clamp are not twisted.
F. Make sure there is no slack in the spark plug
lead when installed within this range as
shown in the illustration.
G. Install the wire harness clamp into the hole
on the battery box.
H. The end of the cover must be above the relay
steps. Make sure the cover does not turn up
around the entire circumference.
I. Relay steps
J. Push in the buzzer coupler up to the inside of
the wire harness branch lead and relay. The
coupler is allowed to protrude out after it is
pushed in.
K. Install the wire harness coupler into the hole
in the bracket.
2-42
CABLE ROUTING
Rear frame (left side view)
2-43
CABLE ROUTING
1. Centerstand lock solenoid coupler

2. Centerstand lock solenoid lead
3. Sidestand switch
4. Sidestand switch lead
5. Starter motor lead
7. Footboard
8. Joint coupler lead
9. Wire harness (seat/fuel lid lock solenoid lead)
10.Rear frame
11.Wire harness
12.Generator cover protector
13.Centerstand lock solenoid cover
A. Install the wire harness clamp into the hole

on the fuel tank bracket.
B. Install the plastic locking tie within this range.
C. Install the plastic locking tie so that the cen-
terstand lock solenoid lead does not go slack
in the space between the centerstand lock
solenoid coupler and the guide of the genera-
tor cover protector.
D. Make sure that the centerstand lock solenoid
lead does not slacken in this range.
E. Install the centerstand lock solenoid lead to
the rib of the generator cover protector. (3
locations)
F. Anti-theft alarm coupler (no connection)
G. Install the clamp of the sidestand switch lead
to the bracket.
H. To the tracking system control unit (except for
XP530E-A)
I. Fasten the wire harness to the footboard with
the plastic locking tie. Position the plastic
locking tie within the range shown in the illus-
tration. Point the end of the plastic locking tie
rearward and place it inside of the footboard.
the rear frame.
K. Route the seat/fuel lid lock solenoid lead
through the rib portion of the filler cover.
L. The end of the plastic locking tie should face
the inside without being cut.
M. Route the centerstand lock solenoid lead
through the notch section of the centerstand
lock solenoid cover.
N. Install the plastic locking tie between the wire
harness clamp and the centerstand lock sole-
noid coupler. Make sure the plastic locking tie
does not come into contact with the bare
wire. The end of the plastic locking tie should
face downward without being cut.
O. Fasten the white tape section of the starter
motor lead with the plastic locking tie.
P. Connect the fuel pump coupler securely to
the fuel pump.
2-44
CABLE ROUTING
Frame (left side view)
2-45
CABLE ROUTING
1. Stator coil coupler

2. Sidestand relay
3. Turn signal/hazard relay
4. Radiator fan motor relay
5. Seat heater relay (power) (for XP530D-A)
6. Seat heater relay (control) (for XP530D-A)
7. Windshield drive unit relay (down) (for
XP530D-A)
8. Windshield drive unit relay (up) (for XP530D-
A)
9. Tail/brake light lead (left)
10.Crankshaft position sensor coupler
11.Stator coil assembly lead
12.Rear frame
13.Wire harness
15.Clamp
16.Mudguard assembly
17.Tail/brake light cover
A. Install the wire harness clamp within this

range.
B. Connect the rear turn signal light lead by
matching the colors of the coupler (left: black,
right: white).
Connect the license plate light lead (blue-
black). (Color does not matter.)
C. The order of arrangement of the lead does
not matter as long as it is installed within this
range.
D. Install the plastic locking tie within this range.
E. Install the wire harness clamp to the rounded
end of the rib.
F. Fasten the white tape section of the stator
coil assembly lead and wire harness with the
plastic locking tie. The end of the plastic lock-
ing tie should be cut facing the outside.
G. Fasten the tape portion of each lead with the
clamp.
White tape: Wire harness, seat heater lead
(for XP530D-A)
Yellow tape: Mudguard assembly lead
It should be okay as long as the clamp is
aligned roughly to the tape section of each
lead.
H. The end of the plastic locking tie should face
the inside without being cut.
I. Route the rear turn signal light lead (left/right)
and license plate light lead through the hole
in the tail/brake light cover.
the rear frame.
K. Adjust the stator coil assembly lead and wire
harness to the position of the wire harness
clamp and fasten them with the plastic lock-
ing tie.
2-46
CABLE ROUTING
Frame (top view)
2-47
CABLE ROUTING
1. Fuse box 4 (for XP530D-A)

2. Fuse box 5 (for XP530D-A)
3. Fuse box 2
4. Starter relay lead
5. Fuse box 1
6. Fuse box 3
7. ABS ECU coupler
8. Intake air pressure sensor
9. Lean angle sensor
10.Canister purge hose
11.Coolant temperature sensor
12.Coupler cover
14.Meter assembly lead
15.Handlebar switch lead (left/right)/Grip warmer
16.Front brake hose (hydraulic unit to front brake
caliper)
17.Rear brake hose (rear brake master cylinder
to hydraulic unit)
18.Front brake hose (front brake master cylinder
to hydraulic unit)
19.Windshield drive unit cable
20.Fuel tank fitting bracket
21.Injector #2
22.Injector #1
23.Throttle servo motor lead
A. Route the coolant temperature sensor lead

below the canister purge hose.
B. Route the wire harness below the protruding
portion of the fuel tank bracket.
C. Install the clamp into the screw hole in the
bracket. (except for XP530E-A)
D. Install the clamp so that it touches the cou-
pler side within the range shown in the illus-
tration.
E. 0–10 mm (0–0.39 in)
F. Install the coupler cover so that the white
paint mark is on top.
G. Make sure the plastic locking tie does not
come into contact with the fuel tank.
H. After connecting the coupler to the meter,
insert it until the coupler cover contacts the
bottom of the meter.
I. Route the leads on the inside of the bracket.
J. Route these leads between the steel tube of
the front brake hose (hydraulic unit to front
brake caliper) and the headlight stay.
K. Route the wire harness between the lean
angle sensor and the fuel tank fitting bracket.
L. The end of the clamp should face the bottom
without being cut.
2-48
CABLE ROUTING
Frame (top view)
2-49
CABLE ROUTING
1. Fuel pump lead

2. Seat/fuel lid lock solenoid coupler
3. Seat lock cable
4. Tail/brake light lead (right)
5. Tail/brake light
6. Tail/brake light lead (left)
7. Storage box light
8. Windshield drive unit relay (up) (for XP530D-
A)
9. Windshield drive unit relay (down) (for
XP530D-A)
10.Seat heater relay (control) (for XP530D-A)
11.Seat heater relay (power) (for XP530D-A)
12.Radiator fan motor relay
13.Turn signal/hazard relay
14.Sidestand relay
15.Wire harness
A. To fuel pump
B. Route the lead along the edge of the filler
cover.
C. Make sure the seat lock cable does not get
caught.
D. Install the seat/fuel lid lock solenoid lead to
the rib of the filler cover.
2-50
CABLE ROUTING
Handlebar (top and left side view) (for XP530E-A/XP530-A)
2-51
CABLE ROUTING

2. Handlebar cover
3. Throttle cable (decelerator cable)
4. Throttle cable (accelerator cable)
5. Front brake hose (front brake master cylinder
to hydraulic unit)
6. Front brake master cylinder
7. Throttle grip
8. Handlebar switch (right)
9. Handlebar switch (left)
10.Handlebar grip
11.Rear brake master cylinder
to hydraulic unit)
13.Brake hose holder
14.Rear brake lock lever
A. Route the rear brake lock cable through the

hole in the handlebar cover.
B. Route through the cable guide in the order of
the throttle cable (decelerator cable) followed
by throttle cable (accelerator cable).
C. Route the handlebar switch lead (right) on
top of and at the back of the handlebar.
D. Route the handlebar switch lead (left) on top
of and at the back of the handlebar.
E. Turn the rear brake lock lever up to the posi-
tion shown in the illustration before installing
the rear brake lock cable.
F. The opening of the clamp should face the
front.
2-52
CABLE ROUTING
Handlebar (front view) (for XP530E-A/XP530-A)
2-53
CABLE ROUTING
1. Brake master cylinder X. Clamp installing procedure

2. Front brake hose (front brake master cylinder 1. Mark the reference point on the lead of
to hydraulic unit) each component.
2. Align the marking of each lead and fasten
3. OFF/LOCK switch coupler with the clamp A.
4. Parking/Unlock switch coupler 3. Fasten the wire harness with the clamp B
5. Throttle cable (decelerator cable) at a position that is located 275–285 mm
(10.83–11.22 in) from the end of clamp A.
Y. Reference point
7. Wire harness
Z. Fasten the handlebar switch lead (left) and
8. Front brake master cylinder handlebar switch lead (right) with the clamp.
9. Rear brake master cylinder AA. Relative angle between clamp A and clamp
10.Bracket B: –15–15
11.Clamp AB. The end of the clamp should face the right
12.Handlebar switch lead (right) without being cut.
13.Handlebar switch lead (left) AC. Route the throttle cables thorough the right
14.Handlebar cover side opening in the handlebar cover as
shown in the illustration.
A. Route the throttle cable (accelerator cable) in
front of the throttle cable (decelerator cable).
B. Route the rear brake hose behind the leads
around the handlebar and throttle cables.
C. Route the wire harness in front of the leads
around the handlebar.
D. Clamp A
E. Clamp B
F. Route the rear brake hose on top of the front
brake hose.
G. Route the front brake hose behind the throttle
cables.
H. Connect the brake light switch from the
inside. (left/right)
I. The metal part of the front brake hose should
come into contact with the guide section of
the brake master cylinder.
J. Attach the front brake hose with the white
paint mark on the metal part facing the front.
K. Attach the rear brake hose with the yellow
L. Route the metal part of the rear brake hose
between the guides of the brake master cylin-
der.
M. Consolidate the leads around the handlebar
and fasten them with the clamp. See the
clamp A fixed position details for more
details.
N. Face the end of the wire harness clamp
toward the left.
O. Clamp A fixed position details
P. Right side of the vehicle
Q. Left side of the vehicle
R. 245–255 mm (9.65–10.04 in): Case end face
S. 285–295 mm (11.22–11.61 in): Case end
face
T. Interval between the clamp A end and the
clamp B end: 275–285 mm (10.83–11.22 in)
U. Make sure there is no slack, break, entangl-
ing, etc., within this interval for each harness.
V. 205–215 mm (8.07–8.46 in)
W. Positioning white tape
2-54
CABLE ROUTING
Handlebar (top and left side view) (for XP530D-A: Model for routing the grip warmer lead inside the throt-
tle housing)
2-55
CABLE ROUTING

2. Handlebar cover
to hydraulic unit)
7. Throttle grip
9. Grip cancel switch lead
10.Handlebar switch (left)
11.Handlebar grip
to hydraulic unit)
16.Grip cancel switch
17.Grip warmer lead

C. Route the grip warmer lead, handlebar switch
lead (right), and front brake light switch lead
on top of and behind the handlebar.
D. Route the grip cancel switch lead between
the lower handlebar holder and the upper
bracket.
E. Route the grip warmer lead (left), handlebar
switch lead (left), and rear brake light switch
lead on top of and behind the handlebar.
F. Turn the rear brake lock lever up to the posi-
G. Install the grip warmer lead (left) into the slot
in the handlebar switch.
H. Case mating surface of the handlebar switch
I. 90±3
J. Install the grommet of the grip warmer lead
(right) into the slot in the handlebar switch,
and then hold and fasten it with the plate of
the throttle cable (accelerator cable).
K. Apply lithium-soap-based grease to the mov-
ing parts of the grip warmer lead (right) and
the inside of the handlebar switch (shaded
area in the illustration).
L. Fully open position
M. Fully closed position
N. The opening of the clamp should face the
front.
2-56
CABLE ROUTING
Handlebar (top and left side view) (for XP530D-A: Model for routing the grip warmer lead outside the throt-
tle housing)
2-57
CABLE ROUTING

2. Handlebar cover
to hydraulic unit)
7. Throttle grip
9. Grip cancel switch lead
11.Handlebar grip
to hydraulic unit)

C. Route the grip warmer lead, handlebar switch
lead (right), and front brake light switch lead
on top of and behind the handlebar.
D. Route the grip cancel switch lead between
the lower handlebar holder and the upper
bracket.
E. Route the grip warmer lead (left), handlebar
switch lead (left), and rear brake light switch
lead on top of and behind the handlebar.
F. Place the tie of the plastic locking tie in front
of the vehicle without cutting its end.
G. Turn the rear brake lock lever up to the posi-
H. Install the grip warmer lead (left) into the slot
in the handlebar switch.
I. Case mating surface of the handlebar switch
J. 903
K. The opening of the clamp should face the
front.
2-58
CABLE ROUTING
Handlebar (front view) (for XP530D-A: Model for routing the grip warmer lead inside the throttle housing)
2-59
CABLE ROUTING
1. Brake master cylinder Q. Install the rear brake hose with the yellow
2. Front brake hose (front brake master cylinder paint mark on the metal part facing the front.
to hydraulic unit) R. Route the metal part of the rear brake hose
3. OFF/LOCK switch coupler between the guides of the brake master cylin-
der.
4. Parking/Unlock switch coupler
S. Consolidate the leads around the handlebar
5. Throttle cable (decelerator cable) and fasten them with the clamp. See the
6. Throttle cable (accelerator cable) clamp A fixed position details for more
7. Wire harness details.
8. Plate (throttle cable) T. Face the end of the wire harness clamp
toward the left.
9. Grip warmer lead (right)
U. Clamp A fixed position details
V. Right side of the vehicle
11.Front brake master cylinder
W. Left side of the vehicle
X. 330–340 mm (12.99–13.39 in): Collar end
13.Bracket face
14.Clamp Y. 245–255 mm (9.65–10.04 in): Case end face
15.Handlebar switch lead (right) Z. 215–225 mm (8.46–8.86 in): Case end face
16.Front brake light switch lead AA. 360–370 mm (14.17–14.57 in): Grommet
17.Rear brake light switch lead end face
18.Handlebar switch lead (left) AB. 285–295 mm (11.22–11.61 in): Case end
19.Grip warmer lead (left) face
20.Handlebar cover AC. 255–265 mm (10.04–10.43 in): Case end
face
A. Route the throttle cable (accelerator cable) in AD. Interval between the clamp A end and the
front of the throttle cable (decelerator cable). clamp B end: 275–285 mm (10.83–11.22 in)
B. Route the rear brake hose behind the leads AE. Make sure there is no slack, break, entangl-
around the handlebar and throttle cables. ing, etc., within this interval for each harness.
C. Route the wire harness in front of the leads AF. 205–215 mm (8.07–8.46 in)
around the handlebar. AG. Positioning white tape
D. Route the grip cancel switch lead between AH. Clamp installing procedure
the accelerator position sensor coupler and 1. Mark the reference point on the lead of
the wire harness. each component.
E. Clamp A 2. Align the marking of each lead and fasten
F. Clamp B with the clamp A.
3. Fasten the wire harness with the clamp B
G. Route the rear brake hose on top of the front
at a position that is located 275–285 mm
brake hose. (10.83–11.22 in) from the end of clamp A.
H. Arrange the grip cancel switch coupler in AI. Reference point
front of the brake hose and leads around the
handlebar. AJ. Fasten the grip warmer lead (left), grip
warmer lead (right), handlebar switch lead
I. Route the front brake hose behind the throttle (left), handlebar switch lead (right), front
cables.
brake light switch lead, and rear brake light
J. Route the grip warmer lead so that it does not switch lead with the clamp.
get caught between the front brake light AK. Relative angle between clamp A and clamp
switch lead and the handlebar cover.
B: –15–15
K. Route the grip warmer lead inside the han- AL. The end of the clamp should face the right
dlebar cover while routing it behind the front without being cut.
brake light switch.
AM. Route the throttle cables thorough the right
L. Align the blue tape end of the grip warmer side opening in the handlebar cover as
lead with the end of the plastic locking tie to shown in the illustration.
fasten it.
M. 3 mm (0.12 in) or less
N. The plastic locking tie should face downward
with the end cut to 3 mm (0.12 in) or less.
O. The metal part of the front brake hose should
P. Install the front brake hose with the white
2-60
CABLE ROUTING
Handlebar (front view) (for XP530D-A: Model for routing the grip warmer lead outside the throttle hous-
ing)
2-61
CABLE ROUTING
1. Brake master cylinder O. Install the front brake hose with the white
2. Front brake hose (front brake master cylinder paint mark on the metal part facing the front.
to hydraulic unit) P. Install the rear brake hose with the yellow
3. OFF/LOCK switch coupler paint mark on the metal part facing the front.
4. Parking/Unlock switch coupler Q. Route the metal part of the rear brake hose
between the guides of the brake master cylin-
5. Throttle cable (decelerator cable) der.
6. Throttle cable (accelerator cable) R. Consolidate the leads around the handlebar
7. Wire harness and fasten them with the clamp. See the
8. Throttle cable (guide) clamp A fixed position details for more
details.
9. Plate (throttle cable)
S. Face the end of the wire harness clamp
10.Cable guide toward the left.
11.Grip warmer lead (right) T. Clamp A fixed position details
12.Handlebar switch (right) U. Right side of the vehicle
13.Front brake master cylinder V. Left side of the vehicle
14.Rear brake master cylinder W. 330–340 mm (12.99–13.39 in): Collar end
15.Bracket face
16.Clamp X. 245–255 mm (9.65–10.04 in): Case end face
17.Handlebar switch lead (right) Y. 215–225 mm (8.46–8.86 in): Case end face
18.Front brake light switch lead Z. 335–345 mm (13.19–13.58 in): Grommet end
19.Rear brake light switch lead face
20.Handlebar switch lead (left) AA. 285–295 mm (11.22–11.61 in): Case end
21.Grip warmer lead (left) face
22.Handlebar cover AB. 255–265 mm (10.04–10.43 in): Case end
face
A. Route the throttle cable (accelerator cable) in AC. Clamp position: 185–195 mm (7.28–7.68 in)
front of the throttle cable (decelerator cable). AD. Interval between the clamp A end and the
B. Route the rear brake hose behind the leads clamp B end: 275–285 mm (10.83–11.22 in)
around the handlebar and throttle cables. AE. Make sure there is no slack, break, entangl-
C. Route the wire harness in front of the leads ing, etc., within this interval for each harness.
around the handlebar. AF. 221–231 mm (8.70–9.09 in)
D. Route the grip cancel switch lead between AG. Positioning white tape
the accelerator position sensor coupler and AH. Clamp installing procedure
the wire harness. 1. Mark the reference point on the lead of
E. Clamp A each component.
F. Clamp B 2. Align the marking of each lead and fasten
with the clamp A.
G. Route the rear brake hose on top of the front 3. Fasten the wire harness with the clamp B
brake hose.
at a position that is located 275–285 mm
H. Arrange the grip cancel switch coupler in (10.83–11.22 in) from the end of clamp A.
front of the brake hose and leads around the AI. Reference point
handlebar.
AJ. Fasten the grip warmer lead (left), grip
I. Route the front brake hose behind the throttle warmer lead (right), handlebar switch lead
cables. (left), handlebar switch lead (right), front
J. Pass the grip warmer lead in front of the vehi- brake light switch lead, and rear brake light
cle of the cable guide. switch lead with the clamp.
K. Pass the grip warmer lead on the inside of AK. Relative angle between clamp A and clamp
the handlebar cover. B: –15–15
L. After clamping the grip warmer lead with the AL. The end of the clamp should face the right
cable guide, insert the detent projection into without being cut.
the hole in the handlebar switch (right).
AM. Route the throttle cables thorough the right
Then install the cable guide using the screw side opening in the handlebar cover as
while pushing the detent projection against shown in the illustration.
the inside of the vehicle.
M. Install the grommet of the grip warmer lead
so that the surface side of the grommet faces
the handlebar switch (right).
N. The metal part of the front brake hose should
2-62
CABLE ROUTING
Front brake (front, left side and right side view)
2-63
CABLE ROUTING
1. Headlight stay
2. Front brake hose (hydraulic unit to front brake
caliper)
3. Front brake hose (left brake caliper to right
brake caliper)
4. Clamp
5. Front wheel sensor lead
6. Front brake caliper (left)
8. Front brake caliper (right)
9. Brake hose holder
11.Stay
A. To hydraulic unit
B. 4.7–4.9 mm (0.185–0.193 in)
C. Fasten the white tape section of the front
wheel sensor lead and front brake hose with
the clamp. Install the clamp so that the front
wheel sensor lead is located on the right side.
D. Fasten the white tape section of the front
wheel sensor lead and front brake hose with
a clamp. Install the clamp so that the front
wheel sensor lead is located on the back.
E. Install the clamp into the hole in the brake
hose holder.
F. Route the front wheel sensor lead through
the brake hose holder.
G. Install the front brake hose with the paint
mark on the outside.
H. Install the brake hose holder with the rotation
stopper in contact with the headlight stay.
When using the dimension “B”, it is not nec-
essary to let the stopper touch the headlight
stay.
I. Fasten the white tape section of the front
wheel sensor lead with the plastic locking tie.
The plastic locking tie should face downward
with the end cut to 5 mm (0.2 in) or less.
J. Install the stay with the identification mark
facing the front.
K. Install the front brake hose (left brake caliper
to right brake caliper) with the metal part in
contact with the positioning stopper of the
brake caliper. Install the front brake hose
(hydraulic unit to front brake caliper) by align-
ing the metal part to the direction of the metal
part of the front brake hose (left brake caliper
to right brake caliper).
L. Install the front brake hose (left brake caliper
to right brake caliper) with the metal part in
contact with the positioning stopper of the
brake caliper.
2-64
CABLE ROUTING
2-65
CABLE ROUTING
1. Rear frame
2. Rear brake hose (hydraulic unit to rear brake
caliper)
4. Electrical components tray
5. Guide
6. Frame
9. Clamp
10.Fuel tank bracket
11.Cable guide
A. Install the bracket with the rotation stopper in

contact with the rib of the rear frame.
B. Install the brake hose holder with the rotation
stopper in contact with the ribs of the rear
frame.
C. Fasten the protector portion of the rear brake
hose and the protector portion of the rear
wheel sensor lead with the plastic locking tie.
Fasten the protector end of the rear wheel
sensor lead (anywhere within a range of 0–10
mm (0–0.39 in) from the end) with the plastic
locking tie. Make sure the plastic locking tie
will not detach from the protector part of the
brake hose and rear wheel sensor lead.
D. Route the rear brake lock cable in front of the
section where the electrical components tray
and frame are fastened.
E. Route the rear brake hose along the guide of
the electrical components tray.
F. Make sure there is no slack in the rear wheel
sensor lead within this interval.
G. Arrange the rear wheel sensor lead either on
top of, below, or outside the rear brake hose.
H. The end of the plastic locking tie should face
downward without being cut.
I. The opening of the clamp should face the top.
J. The opening of the clamp should face the
right.
K. Route the rear brake lock cable between the
rear frame and the rear brake hose.
L. Fasten the grommet portion of the rear brake
lock cable with the cable guide.
M. Fasten the rear brake hose and white tape
section of the rear wheel sensor lead with the
clamp.
Fasten the brake hose and rear wheel sensor
lead so that the rear wheel sensor lead is
located on the right side.
2-66
CABLE ROUTING
Rear brake (right side view)
2-67
CABLE ROUTING
1. Rear brake lock caliper

3. Holder
caliper)
5. Swingarm (right)
6. Clamp
7. Rear brake caliper
9. Rear brake disc
10.Bracket
11.Rear frame
12.Stay
A. Install the holder with the rotation stopper in

contact with the swingarm.
B. Install the clamp with the clamp in contact
with the protector end of the rear wheel sen-
sor lead.
C. Install the rear brake hose with the rear brake
hose in contact with the stopper of the rear
brake caliper.
D. Route the rear brake lock cable between the
brackets.
E. Route the rear brake hose through the guide
portion of the stay.
F. Fasten the rear brake hose and rear wheel
sensor lead with the clamp so that the rear
wheel sensor is located on the left side.
2-68
CABLE ROUTING
Fuel tank (right side view)
2-69
CABLE ROUTING
1. Fuel tank breather hose (fuel tank to rollover

valve)
2. Fuel tank
3. Clamp
caliper)
5. Fuel tank breather hose (rollover valve to
canister)
6. Coolant pipe
7. Canister purge hose (hose joint to canister)
8. Canister breather hose
9. Canister
10.Rollover valve
11.Clip
A. Install the fuel tank breather hose with the

mark facing the outside. Align the mark on
the hose with the back end of the clamp.
B. Fasten the rear brake hose and fuel tank
breather hose with the clamp. Install the
clamp with the longer side of the fixed section
facing downward, and adjust the position so
that the intersection of the rear brake hose
and fuel tank breather hose is in contact with
the clamp.
C. Install the clamp into the hole in the stay of
the coolant pipe. Fasten the canister purge
hose with the clamp.
D. For the hoses to be installed to the canister,
install the fuel tank breather hose on the out-
side and the canister purge hose on the
inside.
E. Install the fuel tank breather hose with the
mark facing the outside. The end of the fuel
tank breather hose should come into contact
with the rollover valve.
F. The end of the clip should face downward.
Make sure the clip does not ride on top of the
bulge in the hose installing area.
G. Route the fuel tank breather hose and canis-
ter purge hose on the inside of the guide sec-
tion of the bracket.
2-70
CABLE ROUTING
Fuel tank (left side view)
2-71
CABLE ROUTING
1. Fuel tank overflow hose

2. Hose joint
3. Fuel tank cap
4. Filler cover
5. Fuel tank
6. Fuel pump
7. Fuel hose
8. Fuel pump lead
A. Install the fuel tank overflow hose with the

mark facing the outside.
B. Route the fuel tank overflow hose between
the sidestand bracket and the frame.
C. Align the mark on the fuel tank with the mark
on the fuel pump to install the fuel pump.
D. Hold the fuel hose with its paint mark facing
to the right and install the hose to the fuel
tank. After installing the fuel hose to the tank,
the paint mark should face downward.
2-72
CABLE ROUTING
Fuel tank (top view)
2-73
CABLE ROUTING
1. Canister holder
2. Canister
3. Fuel tank breather hose (fuel tank to rollover
valve)
4. Rollover valve
5. Fuel tank
6. Fuel hose
8. Thermostat cover
9. Clip
10.Canister purge hose (hose joint to canister)
11.Canister purge hose (throttle body to hose
joint)
A. Install the canister holder and canister with

the marks facing the top.
B. Install the fuel hose to the fuel rail so that the
paint mark on the fuel hose is facing upward.
C. The end of the clip should face the rear.
Place the clip at a distance of 3 mm (0.12 in)
or more from the hose end. Make sure the
clip does not ride on top of the bulge in the
hose mounting area.
D. Install the canister purge hose to the hose
joint with the longer side facing the rear and
the paint mark facing the right side.
E. The end of the clip should face the rear.
Place the clip at a distance of 2–4 mm (0.08–
0.16 in) from the hose end.
F. Install the canister purge hose with the end in
contact with the throttle body.
G. Fuel tank breather hose end portion
H. 90
I. Install the fuel tank breather hose with the
end portion is aligned within this range.
J. Install the intake air pressure sensor hose
with the intake air pressure sensor base unit
in contact with it.
K. 0–3 mm (0–0.12 in)
2-74
CABLE ROUTING
Air filter case and throttle body (left side view)
2-75
CABLE ROUTING
1. Air filter element

2. Intake manifold
3. Clamp
4. Cylinder head breather hose
5. Throttle body assembly
6. Air filter case
7. Fuel rail
8. Intake air pressure sensor hose
A. Place the clamp at a distance of 1–4 mm

(0.04–0.16 in) from the hose end. The end of
the clamp should face downward.
B. Insert the intake air pressure sensor hose
until it comes into contact with the throttle
body.
2-76
CABLE ROUTING
Radiator (right side view)
2-77
CABLE ROUTING
1. Thermostat outlet hose S. Install the hose clamp with the screw head
2. Thermostat facing the outside.
3. Cooling system air bleed hose T. Install the hose clamp with the screw head
facing the front at an angle of 45 from the
4. Rear brake hose (hydraulic unit to rear brake right side.
caliper)
U. Insert the radiator inlet hose into the radiator
5. Rear brake lock cable until it reaches the end of the punch mark.
6. Coolant reservoir hose V. Make sure the hose clamp does not ride on
7. Radiator cap top of the bulge in the hose mounting area.
8. Leg shield W. 3 mm (0.12 in) or more
9. Horn connector X. 0–1 mm (0–0.04 in)
10.Radiator filler hose Y. Hose plug-in section
11.Coolant pipe Z. Install the clamp at a distance of 2 mm (0.08
12.Radiator in) or more from the hose end.
13.Oil cooler AA. After connecting the oil cooler outlet hose to
the oil cooler, position the end of the hose
14.Oil cooler outlet hose protector so that it is 20–30 mm (0.79–1.18
15.Hose clamp in) from the hose end. It does not matter if the
16.Radiator filler pipe adhesive agent is removed.
17.Clamp AB. Make sure the clamp does not ride on top of
18.Radiator inlet hose the bulge in the hose mounting area.
19.Radiator fan motor lead AC. The end of the clamp should face the front
of the vehicle in the direction parallel to the
20.Radiator bracket coolant pipe.
AD. The end of the clamp should not protrude
A. Install the clamp with its end facing the left. out of this line.
B. Install the clamp so that the paint mark on the AE. Front of the vehicle
radiator filler hose is visible.
C. Install the clamp so that the end section of
the paint mark on the coolant reservoir hose
is visible.
D. Paint mark
E. Install the hose clamp with the screw head
facing the right.
F. Install the clamp with its end facing down-
ward.
G. Install the oil cooler outlet hose with the white
paint mark facing downward.
H. Install the oil cooler outlet hose with the yel-
low paint mark facing the outside.
I. Blue paint mark
J. Install the hose clamp with the screw head
facing the top.
K. Green paint mark
L. Green paint mark. Align the paint marks.
M. Insert the thermostat outlet hose until it
reaches the end of the paint mark on the
coolant pipe.
N. Insert the radiator filler hose until it comes
into contact with the stay of the radiator filler
pipe.
O. Align the stay of the radiator filler pipe with
the paint mark on the radiator filler hose.
P. Install the coolant reservoir hose to the bot-
tom of the radiator filler hose.
Q. The opening of the clamp should face the
right.
R. Insert the radiator inlet hose up to the end of
the blue paint mark on the coolant pipe.
2-78
CABLE ROUTING
Radiator (left side view)
2-79
CABLE ROUTING
1. Thermostat
2. Thermostat outlet hose
3. Coolant hose
4. Oil cooler inlet hose
5. Radiator outlet hose
6. Radiator
7. Coolant reservoir
8. Coolant reservoir breather hose
9. Hose clamp
10.Clamp
11.Oil cooler
12.Clip
A. Install the clamp with its end facing the top.

B. Insert the coolant hose until it reaches the
rounded end of the pipe. Install the coolant
hose with the yellow paint mark facing the
top.
C. Install the clamp with its end facing the front.
D. Install the hose clamp with the screw head
facing the left.
E. Install the clamp with the end facing forward
and downward at an angle of 45 from the
horizontal direction.
F. Install the clamp with the hose clamp in con-
tact with it. 0–10 mm (0–0.39 in)
G. Install the coolant reservoir hose to the clamp
so that the paint mark is visible.
H. Install the clip with its end facing the left.
I. Install the clamp so that the joint section is at
a position relative to the screw head of the
hose clamp as shown in the illustration when
viewed from the rear of the vehicle.
J. Example of bad clamp installing position
K. Make sure the clamp does not ride on top of
the bulge in the hose installing area.
L. 0–1 mm (0–0.04 in)
M. Protrusion shape
N. Align the paint mark with the protrusion
shape.
O. Paint mark
P. Insert the hose until it comes into contact with
the protrusion shape.
Q. 3 mm (0.12 in) or more
R. Align the white paint mark on the radiator out-
let hose with the paint mark on the water
pump inlet pipe.
S. Make sure the hose does not contact the
rounded end of the water pump outlet pipe.
T. 2 mm (0.08 in) or more
U. Insert the hose until it reaches the end of the
paint mark.
V. 35
W. 2.9–3.9
X. Make sure the clip does not ride on top of the
bulge in the hose installing area.
2-80
CABLE ROUTING
Radiator (top view)
2-81
CABLE ROUTING
1. Radiator cap
caliper)
5. Radiator bracket
6. Frame
7. Thermostat outlet hose
8. Thermostat
9. Coolant hose
10.Oil cooler inlet hose
11.Radiator outlet hose
12.Coolant reservoir
13.Canister purge hose (hose joint to canister)
14.Radiator
15.Rear brake lock cable
16.Cooling system air bleed hose
17.Clip
18.Clamp
19.Radiator filler pipe
A. Route the cooling system air bleed hose

between the rear brake hose and the rear
brake lock cable.
B. Route the cooling system air bleed hose
between the fuel tank bracket and the frame.
C. Install the cooling system air bleed hose with
the paint mark facing the top, and then put on
the thermostat cover.
D. Insert the coolant hose until it reaches the
rounded end of the pipe.
E. Install the clamp at a distance of at least 1
mm (0.04 in) or more from the hose end.
Make sure the hose clamp does not ride on
top of the bulge in the hose mounting area.
F. Install the clip with its end facing the left.
G. Insert the coolant reservoir hose until it
comes into contact with the rib of the radiator
filler pipe.
H. Insert the cooling system air bleed hose until
it comes into contact with the rib of the radia-
tor filler pipe.
I. Install the clamp with its end facing the right.
J. Make sure the clip does not ride on top of the
bulge in the hose mounting area.
K. 3 mm (0.12 in) or more
L. Install the clamp so that the paint mark on the
canister purge hose is visible.
M. Install the clamp by aligning it with the end of
the paint mark on the cooling system air
bleed hose.
2-82
CABLE ROUTING
Hydraulic unit assembly (top and front view)
2-83
CABLE ROUTING

caliper)
2. Rear brake hose (rear brake master cylinder
to hydraulic unit)
to hydraulic unit)
4. Front brake hose (hydraulic unit to front brake
caliper)
5. Hydraulic unit
A. Brake hose installation order

1. Install rear brake hose “1” at the indicated
angle. Install front brake hose “3” with the L-
shaped pin in contact with the side of the
hydraulic unit. (The installation order of rear
brake hose “1” and front brake hose “3” of
rear brake hose “2” does not matter.)
2. Install front brake hose “4” with the protru-
sion in contact with the metal part of front
brake hose “3”. Install rear brake hose “2”
with the protrusion in contact with the metal
part of rear brake hose “1”. (The installation
order of front brake hose “4” and rear brake
hose “2” does not matter.)
3. Tighten the mounting bolts of each brake
hose to the specified torque. (In no particular
order)
B. 16.4–16.8
C. 16–20
2-84
CABLE ROUTING
2-85
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE .............................................................................3-1

INTRODUCTION ........................................................................................3-1
1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM ....................................................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART ........................3-1
CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC
TOOL .........................................................................................................3-4
2
CHECKING THE FUEL LINE .....................................................................3-4
CHECKING THE SPARK PLUGS ..............................................................3-5
ADJUSTING THE VALVE CLEARANCE ...................................................3-5
CHECKING THE ENGINE IDLING SPEED ...............................................3-9
SYNCHRONIZING THE THROTTLE BODIES...........................................3-9
CHECKING THE THROTTLE BODY JOINTS .........................................3-11
CHECKING THE EXHAUST SYSTEM.....................................................3-11
CHECKING THE CYLINDER HEAD BREATHER HOSE ........................3-12
CHECKING THE CANISTER ...................................................................3-12
3
ADJUSTING THE EXHAUST GAS VOLUME ..........................................3-12
REPLACING THE AIR FILTER ELEMENT ..............................................3-13
CLEANING THE V-BELT CASE AIR FILTER ELEMENT ........................3-13
CHECKING THE BRAKE OPERATION ...................................................3-14
CHECKING THE BRAKE FLUID LEVEL..................................................3-15
4
ADJUSTING THE FRONT DISC BRAKE.................................................3-15
CHECKING THE FRONT BRAKE PADS .................................................3-16
5
ADJUSTING THE REAR DISC BRAKE ...................................................3-16
CHECKING THE REAR BRAKE PADS ...................................................3-16
CHECKING THE FRONT BRAKE HOSES ..............................................3-16
CHECKING THE REAR BRAKE HOSE ...................................................3-17
BLEEDING THE HYDRAULIC BRAKE SYSTEM ....................................3-17
6
ADJUSTING THE REAR BRAKE LOCK CABLE .....................................3-18
CHECKING THE REAR BRAKE LOCK ...................................................3-19
CHECKING THE REAR BRAKE LOCK PADS.........................................3-19
CHECKING THE WHEELS ......................................................................3-19
CHECKING THE TIRES...........................................................................3-19
CHECKING THE WHEEL BEARINGS .....................................................3-21
CHECKING THE SWINGARM OPERATION ...........................................3-21
CHECKING THE DRIVE BELT ................................................................3-21
DRIVE BELT TENSION............................................................................3-22
7
LUBRICATING THE DRIVE PULLEY AND DRIVE AXLE........................3-23
CHECKING AND ADJUSTING THE STEERING HEAD ..........................3-24
LUBRICATING THE STEERING HEAD...................................................3-25
CHECKING THE CHASSIS FASTENERS ...............................................3-25
LUBRICATING THE LEVERS ..................................................................3-25
8
CHECKING THE SIDESTAND.................................................................3-25
LUBRICATING THE SIDESTAND............................................................3-25
CHECKING THE CENTERSTAND ..........................................................3-26
LUBRICATING THE CENTERSTAND .....................................................3-26
CHECKING THE SIDESTAND SWITCH..................................................3-26
9
CHECKING THE FRONT FORK ..............................................................3-26
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....................3-26
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
(for XP530D-A) ........................................................................................3-26
CHECKING THE CONNECTING ARM AND RELAY ARM......................3-27
CHECKING THE ENGINE OIL LEVEL.....................................................3-27
CHANGING THE ENGINE OIL ................................................................3-28
MEASURING THE ENGINE OIL PRESSURE .........................................3-29
CHECKING THE COOLANT LEVEL........................................................3-30
CHECKING THE COOLING SYSTEM .....................................................3-31
CHANGING THE COOLANT....................................................................3-31
REPLACING THE V-BELT .......................................................................3-33
CHECKING THE BRAKE LIGHT SWITCHES..........................................3-33
CHECKING AND LUBRICATING THE CABLES .....................................3-34
CHECKING THE THROTTLE GRIP.........................................................3-34
CHECKING AND CHARGING THE BATTERY........................................3-35
CHECKING THE FUSES .........................................................................3-35
ADJUSTING THE HEADLIGHT BEAMS..................................................3-35
PERIODIC MAINTENANCE
EAS20022
EAS30022
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
TIP
• The annual checks must be performed every year, except if a distance-based maintenance is
performed instead.
• From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
EAS30614
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

ODOMETER READINGS
CHECK OR MAINTENANCE ANNUAL
NO. ITEM
JOB 1000 km 10000 km 20000 km 30000 km 40000 km CHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
• Check fuel hoses for cracks or

1 * Fuel line damage.     
• Replace if necessary.
• Check condition.  
• Adjust gap and clean.
2 * Spark plugs
• Replace.  
3 * Valve clearance • Check and adjust. Every 40000 km (24000 mi)
• Check engine idle speed.      

4 * Fuel injection
• Check and adjust synchroni-     
zation.
• Check for leakage.

5 * Exhaust system • Tighten if necessary.     
• Replace gaskets if necessary.
Evaporative emis- • Check control system for

6 * sion control sys- damage.  
tem • Replace if necessary.
EAS30615
GENERAL MAINTENANCE AND LUBRICATION CHART

ODOMETER READINGS
NO. ITEM JOB CHECK
1000 km 10000 km 20000 km 30000 km 40000 km
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
• Perform dynamic inspection

1 * Diagnostic sys- using Yamaha diagnostic tool.      
tem check
• Check the fault codes.
2 * Air filter element • Replace.  
• Clean.  
3 * V-belt case air fil-
ter elements
• Replace.  
• Check operation, fluid level,

4 * Front brake and for fluid leakage.      
• Replace brake pads if neces-
sary.
3-1
ODOMETER READINGS
NO. ITEM
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
• Check operation, fluid level,

5 * Rear brake and for fluid leakage.      
• Replace brake pads if neces-
sary.
• Check for cracks or damage.     

6 * Brake hoses
• Replace. Every 4 years
7 * Brake fluid • Change. Every 2 years
Rear brake lock • Check cable length. At the initial interval and 4000 km (2400 mi) after the initial 1000 km (600
8 cable • Adjust if necessary. mi) and every 5000 km (3000 mi) thereafter.
• Check operation.
9 * Rear brake lock      
• Adjust.
• Check runout and for dam-
10 * Wheels age.    
• Check tread depth and for

damage.
11 * Tires • Replace if necessary.     
• Check air pressure.
• Correct if necessary.
12 * Wheel bearings • Check bearing for looseness    

or damage.
• Check belt condition.

• Replace if damaged. At the initial interval and every 10000 km (6000 mi) until 40000 km
13 * Drive belt • Check belt tension. (24000 mi), and every 5000 km (3000 mi) thereafter.
• Adjust if necessary.
Drive pulley and • Lubricate.
14 *  
drive axle
• Check bearing assemblies for
  
looseness.
15 * Steering bearings
• Moderately repack with lith-
 
ium-soap-based grease.
• Make sure that all nuts, bolts
16 * Chassis fasteners and screws are properly tight-     
ened.
Front and rear • Lubricate with silicone

17 brake lever pivot grease.     
shaft
• Check operation.
18 Sidestand, center- • Lubricate with lithium-soap-     
stand
based grease.
• Check operation and replace
19 * Sidestand switch      
if necessary.
• Check operation and for oil
20 * Front fork leakage.    
Shock absorber • Check operation and for oil

21 * leakage.    
assembly • Replace if necessary.
Rear suspension • Check operation.

relay arm and
22 *    
connecting arm
pivoting points
• Change (warm engine before

draining). At the initial interval and when the oil change indicator
23 Engine oil • Check oil level and vehicle for flashes or comes on. 
oil leakage.
Engine oil filter • Replace.

24   
cartridge
3-2
ODOMETER READINGS
NO. ITEM
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
• Check coolant level and vehi-

    
25 * Cooling system cle for coolant leakage.
• Change. Every 3 years
• Replace. When the V-belt replacement indicator flashes [every 20000 km (12000
26 * V-belt mi)]
Front and rear • Check operation.

27 * brake switches      
Moving parts and • Lubricate.

28 * cables     
• Check operation and free

play.
Throttle grip • Adjust the throttle cable free
29 * housing and play if necessary.     
cable • Lubricate the throttle grip
housing, cable and grip
warmer wire.
Lights, signals • Check operation.

30 * and switches • Adjust headlight beam.      
TIP
• Engine air filter and V-belt air filters
• This model’s engine air filter is equipped with a disposable oil-coated paper element, which must not
be cleaned with compressed air to avoid damaging it.
• The engine air filter element needs to be replaced and the V-belt air filter elements need to be ser-
viced more frequently when riding in unusually wet or dusty areas.
• Hydraulic brake service
• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
check the brake fluid levels and fill the reservoirs as required.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-3
EAS32024 EAS30619
CHECKING THE VEHICLE USING THE CHECKING THE FUEL LINE

YAMAHA DIAGNOSTIC TOOL The following procedure applies to all of the fuel,
Use the Yamaha diagnostic tool and check the breather and overflow hoses.
vehicle according to the following procedure. 1. Remove:
1. Remove: • Bottom side cowling
• Battery cover • Side panel
Refer to “GENERAL CHASSIS (1)” on page • Bottom center cowling
4-1. Refer to “GENERAL CHASSIS (1)” on page
2. Remove the protective cap “1”, and then con- 4-1.
nect the Yamaha diagnostic tool to the cou- • Center cover
pler. • Fuel tank cover assembly
• Side cover
Yamaha diagnostic tool USB • Footboard
90890-03256
Yamaha diagnostic tool (A/I)
90890-03254 4-11.
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
2. Check:
• Fuel hose “1”
1 • Fuel tank breather hose “2”
• Fuel tank overflow hose “3”
Cracks/damage  Replace.
Loose connection  Connect properly.
ECA14940
NOTICE
Make sure the fuel tank breather hose is rout-
ed correctly.
3. Check:
• Fault codes
TIP 1
Use the “Diagnosis of malfunction” function of
the Yamaha diagnostic tool to check the fault
codes. For information about using the Yamaha
diagnostic tool, refer to the operation manual
that is included with the tool.
Fault code number is displayed  Check and
repair the probable cause of the malfunction.
Refer to “TROUBLESHOOTING DETAILS
(FAULT CODE)” on page 8-63.
2
4. Perform:
• Dynamic inspection
TIP
Use the “Dynamic inspection” function of the
Yamaha diagnostic tool version 3.0 and after to
perform the dynamic inspection. For information
about using the Yamaha diagnostic tool, refer to
the operation manual that is included with the
tool.
5. Install:
• Battery cover
4-1.
3-4
Damage/wear  Replace the spark plug.

3 • Insulator “2”
Abnormal color  Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
• Spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
• Spark plug gap “a”
(with a wire thickness gauge)
Out of specification  Regap.
3. Install:
• Fuel tank Spark plug gap
Refer to “FUEL TANK” on page 7-1. 0.7–0.8 mm (0.028–0.031 in)
• Footboard
• Side cover
• Fuel tank cover assembly
• Center cover
4-11.
• Bottom center cowling
• Side panel
• Bottom side cowling
4-1.
8. Install:
EAS30620
CHECKING THE SPARK PLUGS • Spark plug

The following procedure applies to all of the Spark plug
spark plugs. 13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
1. Remove:
R.
• Bottom side cowling TIP

• Side panel Before installing the spark plug, clean the spark
• Radiator cover plug and gasket surface.
9. Connect:
4-1.
• Spark plug cap
2. Disconnect:
10.Install:
• Spark plug cap
• Radiator cover
3. Remove:
• Spark plug
ECA13320 • Side panel
NOTICE Refer to “GENERAL CHASSIS (1)” on page
Before removing the spark plugs, blow away 4-1.
any dirt accumulated in the spark plug wells EAS30622
with compressed air to prevent it from falling ADJUSTING THE VALVE CLEARANCE
into the cylinders. The following procedure applies to all of the
valves.
4. Check:
• Spark plug type TIP
• Valve clearance adjustment should be made
Incorrect  Change.
on a cold engine, at room temperature.
Manufacturer/model • When the valve clearance is to be measured or
NGK/CR7E adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
5. Check:
• Electrode “1”
3-5
1. Remove:
• Windshield
• Front cover
• Windshield inner panel
• Meter assembly 2
• Rearview mirror
• Side panel
• Radiator cover
• Front cowling assembly
6. Measure:
• Leg shield assembly
• Valve clearance
Out of specification  Adjust.
4-1.
• Center cover Valve clearance (cold)
• Fuel tank cover assembly Intake
• Side cover 0.15–0.22 mm (0.0059–0.0087 in)
• Footboard Exhaust
Refer to “GENERAL CHASSIS (2)” on page 0.25–0.32 mm (0.0098–0.0126 in)
4-11.
2. Remove: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Fuel tank a. Turn the crankshaft clockwise.

3. Remove:
• Air filter case
• Throttle body
• Intake manifold
Refer to “THROTTLE BODY” on page 7-5.
4. Remove:
• Spark plugs
• Cylinder head cover
• Cylinder head cover gasket
Refer to “CAMSHAFTS” on page 5-7. b. When piston #1 is at TDC on the compres-
5. Remove: sion stroke, align the “I” mark “a” on the gen-
• Timing mark accessing plug “1” erator rotor with the mark “b” on the generator
• Crankshaft end access cover “2” cover.
TIP
• TDC on the compression stroke can be found
1 when the cylinder #1 camshaft lobes are
turned away from each other.
• In order to be sure that the piston is at TDC, the
alignment mark “c” on the intake camshaft
sprocket and the alignment mark “d” on the ex-
haust camshaft sprocket must align with the
cylinder head mating surface as shown in the
illustration.
3-6
d. To measure the valve clearances of the other

cylinders, starting with cylinder #1 at TDC,
b
turn the crankshaft clockwise as specified in
the following table.
a A 0˚ 360˚ 720˚
#1 C
B
#2 C
A. Degrees that the crankshaft is turned clock-

wise
B. Cylinder
C. Combustion cycle
Cylinder #2 360
c. Measure the valve clearance with a thickness ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

gauge “1”. 7. Remove:
• Camshafts
TIP
• Refer to “CAMSHAFTS” on page 5-7.
• When removing the timing chain and cam-
shafts, fasten the timing chain with a wire to re-
trieve it if it falls into the crankcase.
8. Adjust:
• Valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
TIP a. Remove the valve lifter “1” and the valve pad
• If the valve clearance is incorrect, record the “2” with a valve lapper “3”.
measured reading. Valve lapper
• Measure the valve clearance in the following 90890-04101
sequence. Valve lapping tool
YM-A8998
Valve clearance measuring sequence
Cylinder #1  #2 TIP
• Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
#2 #1 crankcase.
• Make a note of the position of each valve lifter
“1” and valve pad “2” so that they can be in-
stalled in the correct place.
A
A. Front
3-7
Example:
1.55 mm (0.061 in) + 0.03 mm (0.001 in) =
1.58 mm (0.062 in)
The valve pad number is 158.
e. Round off the valve pad number according to
the following table, and then select the suit-
able valve pad.
Last digit Rounded value
0, 1, 2 0
3, 4, 5, 6 5
7, 8, 9 10
TIP
Refer to the following table for the available
valve pads.
Valve pad range Nos. 120–240
Valve pad thickness 1.20–2.40 mm (0.047–

0.094 in)
b. Calculate the difference between the speci-
fied valve clearance and the measured valve 25 thicknesses in 0.05
Available valve pads mm (0.002 in) incre-
clearance. ments
Example:
Specified valve clearance = 0.15–0.22 mm Example:
(0.0059–0.0087 in) Valve pad number = 158
Measured valve clearance = 0.25 mm Rounded value = 160
(0.0098 in) New valve pad number = 160
0.25 mm (0.0098 in) - 0.22 mm (0.0087 in) = f. Install the new valve pad “1” and the valve lift-
0.03 mm (0.001 in) er “2”.
c. Check the thickness of the current valve pad. TIP
TIP • Lubricate the valve pad with molybdenum di-
The thickness “a” of each valve pad is marked in sulfide oil.
hundredths of millimeters on the side that touch- • Lubricate the valve lifter (Top side) with molyb-
es the valve lifter. denum disulfide oil.
• Lubricate the valve lifter (Outer side) with en-
Example:
gine oil.
If the valve pad is marked “155”, the pad
• The valve lifter must turn smoothly when rotat-
thickness is 1.55 mm (0.061 in).
ed by hand.
• Install the valve lifter and the valve pad in the
correct place.
d. Calculate the sum of the values obtained in

steps (b) and (c) to determine the required
valve pad thickness and the valve pad num-
ber.
3-8
g. Install the exhaust and intake camshafts, tim- Use the diagnostic code number “67”.
ing chain and camshaft caps. Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE (ECU)” on
Camshaft cap bolt page 9-5.
10 N·m (1.0 kgf·m, 7.4 lb·ft)
b. Check the ISC (Idle Speed Control) learning
T.
R.
value.
TIP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Refer to “CAMSHAFTS” on page 5-7.
• Lubricate the camshaft lobes and camshaft EAS30797
journals with molybdenum disulfide oil. SYNCHRONIZING THE THROTTLE BODIES
• First, install the exhaust camshaft. TIP
• Turn the crankshaft clockwise several full turns Before synchronizing the throttle bodies, check
to seat the parts. the following items:
h. Measure the valve clearance again. • Valve clearance
i. If the valve clearance is still out of specifica- • Spark plugs
tion, repeat all of the valve clearance adjust- • Air filter element
ment steps until the specified clearance is • Throttle body joints
obtained. • Fuel hose
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Exhaust system
• Breather hoses
9. Install:
• All removed parts Checking the throttle body synchronization
TIP 1. Stand the vehicle on a level surface.
For installation, reverse the removal procedure. TIP
Place the vehicle on a maintenance stand.
10.Adjust:
• Throttle grip free play 2. Remove:
Refer to “CHECKING THE THROTTLE • Bottom side cowling
GRIP” on page 3-34. • Side panel
EAS31017
CHECKING THE ENGINE IDLING SPEED Refer to “GENERAL CHASSIS (1)” on page
4-1.
TIP
Prior to checking the engine idling speed, the • Center cover
throttle body synchronization should be adjusted • Fuel tank cover assembly
properly, the air filter element should be clean, • Side cover
and the engine should have adequate compres- • Footboard
sion. Refer to “GENERAL CHASSIS (2)” on page
4-11.
1. Start the engine and let it warm up for several • Fuel tank
minutes. Refer to “FUEL TANK” on page 7-1.
2. Check: 3. Remove:
• Engine idling speed • Intake air pressure sensor hose “1”
Out of specification  Go to next step. • Cap “2”
Engine idling speed
1
1100–1300 r/min
2
3. Check:
• ISC (Idle Speed Control) learning value
“00” or “01”  Check the intake system.
“02”  Clean the throttle bodies.
Refer to “CHECKING AND CLEANING THE
THROTTLE BODIES” on page 7-9.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the Yamaha diagnostic tool.
3-9
4. Install: If out of specification  Adjust the throttle

• Hose “1” body synchronization.
(Parts No.: 5JW-24311-00) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• 3-way joint “2” Adjusting the throttle body synchronization
(Parts No.: 68V-24376-00) 1. Adjust:
• Intake air pressure sensor hose “3” • Throttle body synchronization
• Vacuum gauge “4” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Vacuum gauge a. Start the engine, warm it up for several min-
90890-03094 utes, and then let it run at the specified en-
Vacuummate gine idling speed.
YU-44456
Engine idling speed
1100–1300 r/min
b. Using the throttle body that has the bypass air

screw “1” with a white paint mark as the stan-
4 dard, adjust the other throttle bodies by turn-
ing its bypass air screw in or out.
ECA21300
NOTICE
Do not turn the bypass air screw (white paint
3 mark) of the throttle body that is the stan-
dard. Otherwise, the engine may run roughly
at idle and the throttle bodies may not oper-
ate properly.
TIP
• Turn the bypass air screw using the carburetor
angle driver.
• After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
1 2
• If a bypass air screw was removed, turn the
screw in fully and be sure to synchronize the
5. Install:
throttle bodies.
• Fuel tank
• If the throttle body synchronization can not be
adjusted using the bypass air screw, clean or
6. Check:
replace the throttle bodies.
• Throttle body synchronization
• The difference in vacuum pressure between
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
the throttle bodies should not exceed 1.33 kPa
a. Start the engine, warm it up for several min-
(10 mmHg).
utes, and then let it run at the specified en-
gine idling speed.
Carburetor angle driver 2
Engine idling speed 90890-03173
1100–1300 r/min
b. Check the vacuum pressure.

Difference in vacuum pressure
between the cylinders
0 kPa–1.3 kPa (0 mmHg–10
mmHg, 0 inHg–0.4 inHg)
3-10
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install:
2. Stop the engine and remove the measuring • Center cover
equipment. Refer to “GENERAL CHASSIS (2)” on page
3. Install: 4-11.
• Intake air pressure sensor hose EAS30625
• Cap CHECKING THE EXHAUST SYSTEM

4. Install: The following procedure applies to all of the ex-
• Fuel tank haust pipes and gaskets.
Refer to “FUEL TANK” on page 7-1. 1. Remove:
• Footboard • Bottom side cowling
• Side cover • Side panel
• Fuel tank cover assembly • Bottom center cowling
• Center cover Refer to “GENERAL CHASSIS (1)” on page
Refer to “GENERAL CHASSIS (2)” on page 4-1.
4-11. • Center cover
• Bottom center cowling • Fuel tank cover assembly
• Side panel • Side cover (right)
• Bottom side cowling • Footboard (right)
Refer to “GENERAL CHASSIS (1)” on page Refer to “GENERAL CHASSIS (2)” on page
4-1. 4-11.
5. Adjust: 2. Check:
• Throttle grip free play • Exhaust assembly “1”
Refer to “CHECKING THE THROTTLE Cracks/damage  Replace.
GRIP” on page 3-34. • Gasket “2”
Exhaust gas leaks  Replace.
Throttle grip free play 3. Check:
1.0–3.0 mm (0.04–0.12 in)
Tightening torque
EAS31318
• Exhaust pipe nut “3”
CHECKING THE THROTTLE BODY JOINTS • Exhaust assembly nut (rear) “4”
1. Remove: Exhaust pipe nut
• Center cover 20 N·m (2.0 kgf·m, 15 lb·ft)
T.
Exhaust assembly nut

R.
4-11. 31 N·m (3.1 kgf·m, 23 lb·ft)

2. Check:
• Throttle body joints
3-11
1
1 2
3 1
4. Install: 3. Install:
• Footboard (right) • All removed parts
• Side cover (right) EAS30626
• Fuel tank cover assembly CHECKING THE CANISTER
• Center cover 1. Remove:
Refer to “GENERAL CHASSIS (2)” on page • Bottom side cowling
4-11. • Side panel
• Bottom center cowling • Bottom center cowling
• Side panel Refer to “GENERAL CHASSIS (1)” on page
• Bottom side cowling 4-1.
Refer to “GENERAL CHASSIS (1)” on page • Center cover
4-1. • Fuel tank cover assembly
EAS30623 • Side cover
CHECKING THE CYLINDER HEAD • Footboard
BREATHER HOSE Refer to “GENERAL CHASSIS (2)” on page
1. Remove: 4-11.
• Bottom side cowling • Fuel tank
• Side panel Refer to “FUEL TANK” on page 7-1.
• Bottom center cowling 2. Check:
Refer to “GENERAL CHASSIS (1)” on page • Canister
4-1. • Canister purge hose
• Center cover • Fuel tank breather hose
• Fuel tank cover assembly • Canister breather hose
• Side cover (right) Cracks/damage  Replace.
• Footboard (right) 3. Install:
Refer to “GENERAL CHASSIS (2)” on page • Fuel tank
4-11. Refer to “FUEL TANK” on page 7-1.
2. Check: • Footboard
• Cylinder head breather hose “1” • Side cover
Cracks/damage  Replace. • Fuel tank cover assembly
Loose connection  Connect properly. • Center cover
ECA14920
NOTICE 4-11.
Make sure the cylinder head breather hose is • Bottom center cowling
routed correctly. • Side panel
4-1.
EAS30799
ADJUSTING THE EXHAUST GAS VOLUME

TIP
• Be sure to set the CO density level to standard,
3-12
and then adjust the exhaust gas volume.

• To adjust the exhaust gas volume, use the CO
adjustment mode of the Yamaha diagnostic 1
tool. For more information, refer to the opera-
tion manual of the Yamaha diagnostic tool.
1. Connect the Yamaha diagnostic tool to the
coupler. For information about connecting the
Yamaha diagnostic tool, refer to “YAMAHA
DIAGNOSTIC TOOL” on page 8-62.
Yamaha diagnostic tool USB 4. Install:
90890-03256
• Air filter case cover
Yamaha diagnostic tool (A/I) ECA20710
90890-03254 NOTICE
EAS30628
Never operate the engine without the air filter
REPLACING THE AIR FILTER ELEMENT element installed. Unfiltered air will cause
1. Remove: rapid wear of engine parts and may damage
• Center cover the engine. Operating the engine without the
Refer to “GENERAL CHASSIS (2)” on page air filter element will also affect throttle body
4-11. synchronization, leading to poor engine per-
2. Remove: formance and possible overheating.
• Air filter case cover “1” TIP
• Air filter element “2” When installing the air filter element into the air
filter case cover, make sure that the sealing sur-
faces are aligned to prevent any air leaks.
5. Install:
• Center cover
4-11.
EAS31181
1 CLEANING THE V-BELT CASE AIR FILTER

ELEMENT
1. Remove:
2 • Side panel
4-1.
• Center cover
• Side cover
• Footboard
3. Check: 4-11.
• Air filter element “1” 2. Remove:
Damage  Replace. • V-belt case air filter element (left) “1”
TIP
• Replace the air filter element every 20000 km
(12000 mi) of operation.
• The air filter needs more frequent service if you
are riding in unusually wet or dusty areas.
3-13
5. Check:
3. Remove:
• V-belt case air filter elements
• V-belt case air filter case cover “1”
Damage  Replace.
• V-belt case air filter case “2” ECA13441
• V-belt case air filter element (right) “3” NOTICE
Since the V-belt case air filter element is a
dry type, do not let grease or water contact it.
6. Install:
• V-belt case air filter element (right)
• V-belt case air filter case
• V-belt case air filter case cover
V-belt case air filter case screw
7 N·m (0.7 kgf·m, 5.2 lb·ft)
1 2
T.
V-belt case air filter case cover

R.
screw
7 N·m (0.7 kgf·m, 5.2 lb·ft)
7. Install:
• V-belt case air filter element (left)
V-belt case air filter element joint
clamp (left side)
T.
3.0 N·m (0.30 kgf·m, 2.2 lb·ft)

R.
3 8. Install:
• Footboard
4. Clean:
• Side cover
• V-belt case air filter elements
Blow the compressed air to the outer surface
• Center cover
of the V-belt case air filter element.
4-11.
• Side panel
4-1.
EAS30801
CHECKING THE BRAKE OPERATION

1. Check:
• Brake operation
Brake not working properly  Check the
brake system.
Refer to “FRONT BRAKE” on page 4-40 and
3-14
“REAR BRAKE” on page 4-53. • When refilling, be careful that water does
TIP not enter the brake master cylinder reser-
Drive on the road, operate the front and rear voir. Water will significantly lower the boil-
brakes separately and check to see if the brakes ing point of the brake fluid and could cause
are operating properly. vapor lock.
ECA13540
EAS30632
NOTICE
CHECKING THE BRAKE FLUID LEVEL
Brake fluid may damage painted surfaces
1. Stand the vehicle on a level surface.
and plastic parts. Therefore, always clean up
TIP any spilt brake fluid immediately.
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright. TIP
In order to ensure a correct reading of the brake
2. Check: fluid level, make sure the top of the brake master
• Brake fluid level cylinder reservoir is horizontal.
Below the minimum level mark “a” Add the
specified brake fluid to the proper level. EAS30630
ADJUSTING THE FRONT DISC BRAKE

Specified brake fluid
DOT 4 1. Adjust:
• Brake lever position
(distance “a” from the throttle grip to the brake
a lever)
TIP
LOWER • While pushing the brake lever forward, turn the
adjusting dial “1” until the brake lever is in the
desired position.
• Be sure to align the setting on the adjusting dial
with the arrow mark “2” on the brake lever.
Position #1
Distance “a” is the largest.
Position #5
a Distance “a” is the smallest.
LOWER
A. Front brake
B. Rear brake 1 2
EWA13540
EWA13060
WARNING
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to • After adjusting the brake lever position,
deteriorate, causing leakage and poor make sure the pin on the brake lever holder
brake performance. is firmly inserted in the hole in the adjusting
• Refill with the same type of brake fluid that dial.
is already in the system. Mixing brake fluids • A soft or spongy feeling in the brake lever
may result in a harmful chemical reaction, can indicate the presence of air in the brake
leading to poor brake performance. system. Before the vehicle is operated, the
3-15
air must be removed by bleeding the brake

system. Air in the brake system will consid-
erably reduce in loss of control and possi-
bly an accident. Therefore, check and if
necessary, bleed the brake system.
2
ECA13490
1
a
3
5
NOTICE 4
After adjusting the brake lever position, 2 1

make sure there is no brake drag.
EAS30633 EWA13060
CHECKING THE FRONT BRAKE PADS WARNING

The following procedure applies to all of the • After adjusting the brake lever position,
brake pads. make sure the pin on the brake lever holder
1. Operate the brake. is firmly inserted in the hole in the adjusting
2. Check: dial.
• Front brake pad • A soft or spongy feeling in the brake lever
Wear indicators “1” almost touch the brake can indicate the presence of air in the brake
disc  Replace the brake pads as a set. system. Before the vehicle is operated, the
Refer to “FRONT BRAKE” on page 4-40. air must be removed by bleeding the brake
system. Air in the brake system will consid-
erably reduce in loss of control and possi-
bly an accident. Therefore, check and if
necessary, bleed the brake system.
ECA13490
NOTICE
After adjusting the brake lever position,
make sure there is no brake drag.
1
EAS30634
EAS30631 CHECKING THE REAR BRAKE PADS

ADJUSTING THE REAR DISC BRAKE The following procedure applies to all of the
1. Adjust: brake pads.
• Brake lever position 1. Operate the brake.
(distance “a” from the left side grip to the 2. Check:
brake lever) • Rear brake pad
TIP Wear indicators “1” almost touch the brake
• While pushing the brake lever forward, turn the disc  Replace the brake pads as a set.
adjusting dial “1” until the brake lever is in the Refer to “REAR BRAKE” on page 4-53.
desired position.
• Be sure to align the setting on the adjusting dial
with the arrow mark “2” on the brake lever hold-
er.
Position #1
Distance “a” is the largest.
Position #5
Distance “a” is the smallest.
1
EAS30635
CHECKING THE FRONT BRAKE HOSES

The following procedure applies to all of the
3-16
brake hoses and brake hose holders. the brake master cylinder reservoir to overflow.
1. Check: • When bleeding the ABS, make sure that there
• Brake hose is always enough brake fluid before applying
Cracks/damage/wear  Replace. the brake. Ignoring this precaution could allow
2. Check: air to enter the ABS, considerably lengthening
• Brake hose holder the bleeding procedure.
Loose  Tighten the holder bolt. • If bleeding is difficult, it may be necessary to let
3. Hold the vehicle upright and apply the front the brake fluid settle for a few hours. Repeat
brake several times. the bleeding procedure when the tiny bubbles
4. Check: in the hose have disappeared.
• Brake hose
1. Bleed:
Brake fluid leakage  Replace the damaged
• ABS
hose.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Refer to “FRONT BRAKE” on page 4-40.
a. Fill the brake master cylinder reservoir to the
EAS30636 proper level with the specified brake fluid.
CHECKING THE REAR BRAKE HOSE b. Install the brake master cylinder reservoir di-
1. Check: aphragm.
• Brake hose c. Connect a clear plastic hose “1” tightly to the
Cracks/damage/wear  Replace. bleed screw “2”.
2. Check:
• Brake hose holders
Loose connection  Tighten the holder bolt.
2
3. Hold the vehicle upright and apply the rear
brake several times.
4. Check:
• Brake hose
Brake fluid leakage  Replace the damaged 1
hose.
Refer to “REAR BRAKE” on page 4-53.
EAS30893
BLEEDING THE HYDRAULIC BRAKE 2

SYSTEM
EWA14000
WARNING
Always bleed the brake system when the
brake related parts are removed.
ECA18050
NOTICE
• Bleed the brake system in the following or- 1
der.
• 1st step: Front brake calipers A. Front brake caliper
• 2nd step: Rear brake caliper B. Rear brake caliper
EWA15740
d. Place the other end of the hose into a con-
WARNING tainer.
Bleed the ABS whenever: e. Slowly apply the brake several times.
• the system is disassembled. f. Fully squeeze the brake lever and hold it in
• a brake hose is loosened, disconnected or position.
replaced. g. Loosen the bleed screw.
• the brake fluid level is very low. TIP
• brake operation is faulty. Loosening the bleed screw will release the pres-
TIP sure and cause the brake lever to contact the
• Be careful not to spill any brake fluid or allow
3-17
throttle grip or handlebar grip. 2. Adjust:

• Rear brake lock cable length
h. Tighten the bleed screw and then release the
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
brake lever.
i. Repeat steps (e) to (h) until all of the air bub- a. Turn the rear brake lock cable adjusting nut
bles have disappeared from the brake fluid in “1” in direction “b” or “c” until the specified
the plastic hose. rear brake lock cable free play is obtained.
j. Check the operation of the hydraulic unit. Re- Direction “b”
fer to “HYDRAULIC UNIT OPERATION Rear brake lock cable length increased.
TEST” on page 4-75. Direction “c”
Rear brake lock cable length decreased.
ECA25780
NOTICE
Before checking the operation of the hydrau-
lic unit, always push the OFF/LOCK switch.
k. After operating the ABS, repeat steps (e) to
(i), and then fill the brake master cylinder
reservoir to the proper level with the speci- b
fied brake fluid.
l. Tighten the bleed screw to specification.
Front brake caliper bleed screw c a
1
5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
Rear brake caliper bleed screw

R.
6 N·m (0.6 kgf·m, 4.4 lb·ft) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
m. Fill the brake master cylinder reservoir to the • Clearance between the brake pad and brake
proper level with the specified brake fluid. disc.
Refer to “CHECKING THE BRAKE FLUID
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
LEVEL” on page 3-15.
EWA13110
a. Remove the cap of the rear brake lock adjust-
WARNING ing nut.
After bleeding the hydraulic brake system, b. Loosen the rear brake lock adjusting nut “1”
check the brake operation. slightly.
c. Adjust the piston adjusting bolt “2” so that the
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ wear indicator “3” is placed within the width of
the wear indicator groove “4” when the rear
EAS31425
ADJUSTING THE REAR BRAKE LOCK brake lock is activated.

CABLE Recommended procedure:
EWA18100 Tighten the piston adjusting bolt to 3.0 N·m
WARNING (0.30 kgf·m, 2.2 lb·ft) and then loosen the bolt
Do not use the rear brake lock lever while 1–1/2 turn.
driving.
TIP
Place the vehicle on the centerstand.
1. Measure:
• Rear brake lock cable length “a”
TIP
Measure while the rear brake lock lever is re-
leased.
d. Tighten the rear brake lock adjusting nut
Rear brake lock cable length while holding the piston adjusting bolt so as
43–45 mm (1.69–1.77 in) not to turn the bolt.
3-18
EAS31427
Rear brake lock adjusting nut CHECKING THE REAR BRAKE LOCK PADS
15 N·m (1.5 kgf·m, 11 lb·ft) The following procedure applies to all of the
T.
R.
brake pads.
e. Make sure that the tire can be turned by hand 1. Operate the rear brake lock.
when the rear brake lock is deactivated. 2. Check:
f. Make sure that the wear indicator is placed • Rear brake lock pad
within the width of the wear indicator groove Wear indicators “1” almost touch the brake
when the rear brake lock is activated. disc  Replace the brake pads as a set.
g. Install the cap of the rear brake lock adjusting Refer to “REPLACING THE REAR BRAKE
nut. LOCK PADS” on page 4-67.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31426
CHECKING THE REAR BRAKE LOCK

1. Check:
• Rear brake lock operation
Apply the rear brake lock, and then pushing
the vehicle for properly locks the rear brake 1
lock.
Rear brake lock not working properly 
Check the rear brake lock cable and rear
brake lock pads. EAS31428
Refer to “ADJUSTING THE REAR BRAKE CHECKING THE WHEELS

LOCK CABLE” on page 3-18 and “CHECK- The following procedure applies to both of the
ING THE REAR BRAKE LOCK PADS” on wheels.
page 3-19. 1. Check:
2. Check: • Wheel
• Rear brake lock cable length Damage/out-of-round  Replace.
Out of specification  Adjust. EWA13260
WARNING
Refer to “ADJUSTING THE REAR BRAKE
LOCK CABLE” on page 3-18. Never attempt to make any repairs to the
3. Check: wheel.
• Wear indicator “1” TIP
Check the position of the indicator while ap- After a tire or wheel has been changed or re-
plying the rear brake lock lever. placed, always balance the wheel.
Passed the wear indicator groove “2”  Ad-
just the rear brake lock cable length. EAS31429
Refer to “ADJUSTING THE REAR BRAKE CHECKING THE TIRES

LOCK CABLE” on page 3-18. The following procedure applies to both of the
tires.
2 1 1. Check:
3 • Tire pressure
Out of specification  Regulate.
4. Check:
• Rear brake lock caliper boot “3”
Refer to “REAR BRAKE” on page 4-53.
3-19
EWA13181
WARNING Wear limit (front)

• The tire pressure should only be checked 1.6 mm (0.06 in)
and regulated when the tire temperature Wear limit (rear)
1.6 mm (0.06 in)
equals the ambient air temperature.
• The tire pressure and the suspension must EWA14090
be adjusted according to the total weight WARNING

(including cargo, rider, passenger and ac- After extensive tests, the tires listed below
cessories) and the anticipated riding have been approved by Yamaha Motor Co.,
speed. Ltd. for this model. The front and rear tires
• Operation of an overloaded vehicle could should always be by the same manufacturer
cause tire damage, an accident or an injury. and of the same design. No guarantee con-
NEVER OVERLOAD THE VEHICLE. cerning handling characteristics can be giv-
en if a tire combination other than one
Tire air pressure (measured on approved by Yamaha is used on this vehicle.
cold tires)
1 person Front tire
Front Size
225 kPa (2.25 kgf/cm², 33 psi) 120/70R15M/C(56H)
Rear Manufacturer/model
250 kPa (2.50 kgf/cm², 36 psi) BRIDGESTONE/BATTLAXSCF
2 persons (XP530-A, XP530E-A)
Front DUNLOP/ROADSMART3
225 kPa (2.25 kgf/cm², 33 psi) (XP530D-A)
Rear
280 kPa (2.80 kgf/cm², 41 psi)
Maximum load Rear tire
199 kg (439 lb) (XP530D-A) Size
202 kg (445 lb) (XP530-A, 160/60R15M/C(67H)
XP530E-A) Manufacturer/model
* Total weight of rider, passenger, cargo BRIDGESTONE/BATTLAXSCR
and accessories (XP530-A, XP530E-A)
EWA13190
DUNLOP/ROADSMART3
WARNING (XP530D-A)
It is dangerous to ride with a worn-out tire. EWA13210
When the tire tread reaches the wear limit, re- WARNING
place the tire immediately. New tires have a relatively low grip on the
2. Check: road surface until they have been slightly
• Tire surfaces worn. Therefore, approximately 100 km
Damage/wear  Replace the tire. should be traveled at normal speed before
any high-speed riding is done.
TIP
For tires with a direction of rotation mark “1”:
• Install the tire with the mark pointing in the di-
rection of wheel rotation.
• Align the mark “2” with the valve installation
point.
1. Tire tread depth

2. Side wall
3. Wear indicator
3-20
EAS30641 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE WHEEL BEARINGS
3. Check:
• Drive belt
wheel bearings.
Exposed cogs or external cracks “A”  Re-
1. Check:
place.
• Wheel bearings
Missing teeth “B”  Replace.
Refer to “FRONT WHEEL” on page 4-22 and
Hook wear “C”  Replace.
“REAR WHEEL” on page 4-31.
Stone damage “D”, “E”  Replace.
EAS30802 Internal tooth cracks (hairline) “F”  OK to
CHECKING THE SWINGARM OPERATION run, but monitor condition.
1. Check: Chipping (not serious) “G”  OK to run, but
• Swingarm operation monitor condition.
Swingarm not working properly  Check the Fuzzy edge cord “H”  OK to run, but moni-
swingarm. tor condition.
Refer to “REMOVING THE SWINGARM” on Edgewear of cogs (or belt) “I”  OK to run,
page 4-108. but monitor condition.
2. Check: Refer to “CHECKING THE DRIVE BELT” on
• Swingarm excessive play page 4-101.
Refer to “REMOVING THE SWINGARM” on Tooth cloth wear “J”  Replace.
page 4-108. Side cracks (hairline) “K”  Replace.
EAS31431
A B
CHECKING THE DRIVE BELT
1. Remove:
• Drive belt upper guard and lower guard
Refer to “REAR WHEEL” on page 4-31 and
“BELT DRIVE” on page 4-100.
2. Clean:
• Drive belt
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wipe the drive belt with a clean cloth.
b. Put the drive belt in a mixture of mild deter- C D
gent and water. Then, remove any dirt from
the drive belt.
c. Remove the drive belt from the mixture and
rinse it off with clean water. Then, let the drive
belt thoroughly dry.
3-21
ECA25750
E NOTICE
A drive belt that is too tight will overload the
engine and other vital parts, and one that is
too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
the drive belt tension within the specified
limits.
TIP
Measure the drive belt tension when the drive
F G belt is at room temperature, and when the drive
belt is dry.
TIP
Place the vehicle on the centerstand.
2. Remove the drive belt upper guard “1”.
H I
3. Tap the drive belt and measure the vibration

frequency.
• Drive belt tension (vibration frequency)
J K Out of specification  Adjust.
Tension meter (TEXA)
90890-03258
Drive belt vibration frequency

74–94 Hz
TIP
Before using the tension meter, read the instruc-
4. Install: tion manual.
• Drive belt
Refer to “BELT DRIVE” on page 4-100. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Drive belt upper guard and lower guard a. Face the microphone part “1” of the tension
Refer to “REAR WHEEL” on page 4-31. meter to the drive belt.
b. Position the microphone part of the tension
EAS32399
meter on the belt within 10 mm (0.39 in).
DRIVE BELT TENSION
Checking the drive belt tension c. Set the microphone part of the tension meter
EWA13120 at the intermediate distance between the
WARNING drive pulley and the rear wheel pulley.
Securely support the vehicle so that there is
no danger of it falling over.
3-22
d. Tap with the suitable stick “2” to vibrate the

belt.
1
e. Repeat the measurement 3 times at different
part, and calculate the average of the read b
values.
1 a
3. Check the difference in the distance “c” be-

tween the left and right sides should be 0.8
2 mm (0.03 in) or less.
4. Tighten the wheel axle nut to specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Rear wheel axle nut
160 N·m (16 kgf·m, 118 lb·ft)
Adjusting the drive belt tension
T.
R.
EWA13120
5. Tighten the locknuts to specification.
WARNING
Securely support the vehicle so that there is Drive belt adjusting locknut
no danger of it falling over. 16 N·m (1.6 kgf·m, 12 lb·ft)
T.
R.
1. Loosen the wheel axle nut and both left and 6. Check the difference in the distance “c” be-
right locknuts “1”. tween the left and right sides is within 0.8 mm
(0.03 in).
7. Use the tension meter and measure the drive
belt tension again.
8. Measure and adjust until proper drive belt
tension within specification value is obtained.
EAS31433
LUBRICATING THE DRIVE PULLEY AND

1 DRIVE AXLE
1. Remove:
• Drive belt upper guard and lower guard
2. Turn both left and right adjusting bolts “1” in Refer to “REAR WHEEL” on page 4-31.
direction “a” or “b” equivalently and adjust un- 2. Remove:
til proper drive belt tension within specified • Drive belt
value is obtained. Refer to “BELT DRIVE” on page 4-100.
3. Remove:
Direction “a” • Drive pulley cover
Drive belt tension vibration frequency Refer to “BELT DRIVE” on page 4-100.
value is increased. • Dust cover
Direction “b”
Refer to “BELT DRIVE” on page 4-100.
Drive belt tension vibration frequency
value is decreased. • Drive pulley assembly
4. Clean:
• Drive axle
• Drive pulley assembly inner part
5. Lubricate:
• Drive axle
TIP
Lubricate portion “a” of the drive axle with
grease.
3-23
8. Adjust:
Recommended lubricant • Drive belt tension
YAMAHA GREASE “J” (Shell Al-
Refer to “DRIVE BELT TENSION” on page
vania EP Grease R0®)
3-22.
EAS30645
CHECKING AND ADJUSTING THE

STEERING HEAD
EWA13120
WARNING
TIP
Place the vehicle on a maintenance stand so
a
that the front wheel is elevated.
2. Check:
• Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
a
Binding/looseness  Adjust the steering
head.
3. Remove:
• Upper bracket
Refer to “STEERING HEAD” on page 4-96.
6. Lubricate: 4. Adjust:
• Drive pulley assembly inner part “a” • Steering head
Recommended lubricant ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
YAMAHA GREASE “J” (Shell Al- a. Remove the lock washer “1”, the upper ring
vania EP Grease R0®) nut “2”, and the rubber washer “3”.
b. Loosen the lower ring nut “4” and then tighten

it to specification with a steering nut wrench
“5”.
TIP
• Set a torque wrench at a right angle to the
steering nut wrench.
• Move the steering to the left and right a couple
of time to check that it moves smoothly.
a
7. Install:
• All removed parts
3-24
5 1
a
4 b
3
Steering nut wrench ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

90890-01403 5. Install:
Exhaust flange nut wrench • Upper bracket
YU-A9472 Refer to “STEERING HEAD” on page 4-96.
EAS30646
Lower ring nut (initial tightening LUBRICATING THE STEERING HEAD
torque) 1. Lubricate:
T.
52 N·m (5.2 kgf·m, 38 lb·ft)

R.
• Upper bearing
• Lower bearing
c. Loosen the lower ring nut completely, then • Bearing race
tighten it to specification.
EWA13140
Recommended lubricant
WARNING Lithium-soap-based grease
Do not overtighten the lower ring nut.
EAS31186
Lower ring nut (final tightening CHECKING THE CHASSIS FASTENERS

torque) Make sure that all nuts, bolts, and screws are
properly tightened.
T.
16 N·m (1.6 kgf·m, 12 lb·ft)

R.
Refer to “CHASSIS TIGHTENING TORQUES”

d. Check the steering head for looseness or on page 2-13.
binding by turning the front fork all the way in EAS30648
both directions. If any binding is felt, remove LUBRICATING THE LEVERS
the lower bracket and check the upper and Lubricate the pivoting point and metal-to-metal
lower bearings. moving parts of the levers.
Refer to “STEERING HEAD” on page 4-96.
e. Install the rubber washer “3”. Recommended lubricant
f. Install the upper ring nut “2”. Silicone grease
g. Finger tighten the upper ring nut “2”, then
EAS30650
align the slots of both ring nuts. If necessary, CHECKING THE SIDESTAND
hold the lower ring nut and tighten the upper 1. Check:
ring nut until their slots are aligned. • Sidestand operation
h. Install the lock washer “1”. Check that the sidestand moves smoothly.
TIP Rough movement  Repair or replace.
Make sure the lock washer tabs “a” sit correctly
in the ring nut slots “b”. EAS30651
LUBRICATING THE SIDESTAND

Lubricate the pivoting point, metal-to-metal mov-
ing parts and spring contact point of the sides-
tand.
Lithium-soap-based grease
3-25
EAS30856 EAS30808
CHECKING THE CENTERSTAND CHECKING THE REAR SHOCK ABSORBER

1. Check: ASSEMBLY
• Centerstand operation 1. Check:
Check that the centerstand moves smoothly. • Rear shock absorber assembly operation
Rough movement  Repair or replace. Push down hard on the seat several times
EAS30857
and check if the rear shock absorber rebound
LUBRICATING THE CENTERSTAND smoothly.
Lubricate the pivoting point, metal-to-metal mov- Rough movement  Replace.
ing parts and spring contact point of the center- Refer to “REAR SHOCK ABSORBER AS-
stand. SEMBLY” on page 4-102.
2. Check:
Recommended lubricant • Rear shock absorber assembly
Lithium-soap-based grease Gas leaks/oil leaks  Replace.
Refer to “REAR SHOCK ABSORBER AS-
EAS30652
SEMBLY” on page 4-102.
CHECKING THE SIDESTAND SWITCH
Refer to “CHECKING THE SWITCHES” on EAS30655
page 8-221. ADJUSTING THE REAR SHOCK ABSORBER

ASSEMBLY (for XP530D-A)
EAS30653 EWA13120
CHECKING THE FRONT FORK WARNING

1. Stand the vehicle on a level surface. Securely support the vehicle so that there is
EWA13120
WARNING no danger of it falling over.

Securely support the vehicle so that there is Spring preload
no danger of it falling over. ECA13590
NOTICE
2. Check: Never go beyond the maximum or minimum
• Inner tube adjustment positions.
Damage/scratches  Replace.
• Front fork leg 1. Adjust:
Oil leaks between inner tube and outer tube • Spring preload
 Replace the oil seal. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3. Hold the vehicle upright and apply the front a. Adjust the spring preload with the special
brake. wrench “1” included in the owner’s tool kit.
4. Check: b. Turn the adjusting ring “2” in direction “a” or
• Front fork operation “b”.
Push down hard on the handlebar several c. Align the desired position on the adjusting
times and check if the front fork rebounds ring with the stopper “3”.
smoothly.
Rough movement  Repair. Direction “a”
Spring preload is increased (suspen-
Refer to “FRONT FORK” on page 4-87.
sion is harder).
Direction “b”
Spring preload is decreased (suspen-
sion is softer).
Spring preload
Adjustment value (Soft)
7 (XP530D-A)
Adjustment value (STD)
4 (XP530D-A)
Adjustment value (Hard)
1 (XP530D-A)
3-26
2
3 b
b
a
1 1 a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Rebound damping EAS30809

ECA13590
NOTICE CHECKING THE CONNECTING ARM AND

RELAY ARM
Never go beyond the maximum or minimum 1. Check:
adjustment positions. • Rear shock absorber assembly operation
1. Adjust: Rough movement  Repair.
• Rebound damping Refer to “REAR SHOCK ABSORBER AS-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ SEMBLY” on page 4-102.
a. Turn the adjusting screw “1” in direction “a” or EAS30656
“b”. CHECKING THE ENGINE OIL LEVEL
Direction “a”
Rebound damping is increased (sus- TIP
pension is harder). • Place the vehicle on the centerstand.
Direction “b” • Make sure the vehicle is upright.
Rebound damping is decreased (sus- 2. Start the engine, warm it up for several min-
pension is softer). utes, and then turn it off.
3. Check:
Rebound damping • Engine oil level
Minimum (soft) The engine oil level should be between the
3 turn(s) in direction “b”* minimum level mark “a” and maximum level
Standard mark “b”.
1.25 turn(s) in direction “b”* Below the minimum level mark  Add the
Maximum (hard) recommended engine oil to the proper level.
Adjusting screw fully turned in
direction “a”
* With the adjusting screw fully turned in di-
rection “a”
TIP
To obtain a precise adjustment, it is advisable to b
check the actual total number of turns of the a
damping force adjusting mechanism. This ad-
justment range may not exactly match the spec-
ifications listed due to small differences in
production.
3-27
Recommended brand
YAMALUBE 3
SAE viscosity grades 2
10W-40
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
ECA13361
NOTICE
• Engine oil also lubricates the clutch and the
wrong oil types or additives could cause 4. Drain:
clutch slippage. Therefore, do not add any • Engine oil
chemical additives or use engine oils with a (completely from the crankcase)
grade of “CD” or higher and do not use oils 5. If the oil filter cartridge is also to be replaced,
labeled “ENERGY CONSERVING II”. perform the following procedure.
• Do not allow foreign materials to enter the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
crankcase. a. Remove the oil filter cartridge “1” with an oil

filter wrench “2”.
TIP
Before checking the engine oil level, wait a few Oil filter wrench
minutes until the oil has settled. 90890-01426
Oil filter wrench
4. Start the engine, warm it up for several min- YU-38411
utes, and then turn it off.
5. Check the engine oil level again.
TIP
Before checking the engine oil level, wait a few
minutes until the oil has settled.
2
EAS30657
CHANGING THE ENGINE OIL

1. Start the engine, warm it up for several min-
utes, and then turn it off. 1
2. Place a container under the engine oil drain
bolt.
3. Remove: b. Lubricate the O-ring “3” of the new oil filter
• Engine oil filler cap “1” cartridge with a thin coat of lithium-soap-
(along with the O-ring) based grease.
ECA13390
• Engine oil drain bolt “2”
NOTICE
(along with the O-ring)
• Gasket “3” Make sure the O-ring “3” is positioned cor-
rectly in the groove of the oil filter cartridge.
1
c. Tighten the new oil filter cartridge to specifi-
3-28
cation with an oil filter wrench.

Oil filter cartridge 1
17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• Gasket New
• Engine oil drain bolt
(along with the O-ring)
TIP
Lubricate the O-ring of the engine oil drain bolt c. Start the engine and keep it idling until engine
with a thin coat of lithium-soap-based grease. oil starts to seep from the oil check bolt. If no
engine oil comes out after one minute, turn
Engine oil drain bolt the engine off so that it will not seize.
43 N·m (4.3 kgf·m, 32 lb·ft) d. Check the engine oil passages, the oil filter
cartridge and the oil pump for damage or
T.
R.
7. Fill: leakage.
• Crankcase Refer to “OIL PUMP” on page 5-59.
(with the specified amount of the recom- e. Start the engine after solving the problem(s)
mended engine oil) and check the engine oil pressure again.
f. Tighten the oil check bolt to specification.
Engine oil quantity
Quantity (disassembled) Engine oil check bolt
3.50 L (3.70 US qt, 3.08 Imp.qt) 15 N·m (1.5 kgf·m, 11 lb·ft)
T.
Oil change
R.
2.60 L (2.75 US qt, 2.29 Imp.qt) g. Install the bottom side cowling and bottom
With oil filter removal center cowling.
2.90 L (3.07 US qt, 2.55 Imp.qt) Refer to “GENERAL CHASSIS (2)” on page
4-11.
8. Install: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Engine oil filler cap
(along with the O-ring New ) EAS30810
9. Start the engine, warm it up for several min- MEASURING THE ENGINE OIL PRESSURE
utes, and then turn it off. 1. Check:
10.Check: • Engine oil level
• Engine Below the minimum level mark  Add the
(for engine oil leaks) recommended engine oil to the proper level.
11.Check: 2. Start the engine, warm it up for several min-
• Engine oil level utes, and then turn it off.
Refer to “CHECKING THE ENGINE OIL ECA13410
NOTICE
12.Check: When the engine is cold, the engine oil will
• Engine oil pressure have a higher viscosity, causing the engine
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ oil pressure to increase. Therefore, be sure
a. Remove the bottom side cowling and bottom to measure the engine oil pressure after
center cowling. warming up the engine.
Refer to “GENERAL CHASSIS (2)” on page 3. Remove:
4-11. • Engine oil pressure check point plug “1”
b. Slightly loosen the oil check bolt “1”. (Bottom of the crankcase)
EWA12980
WARNING
The engine, muffler and engine oil are ex-
tremely hot.
3-29
6. Install:
• Engine oil pressure check point plug
TIP
Lubricate the O-ring of the engine oil pressure
check point plug with a thin coat of lithium-soap-
based grease.
1 Engine oil pressure check point

plug
T.
12 N·m (1.2 kgf·m, 8.9 lb·ft)
R.
4. Install: EAS30811
• Oil pressure gauge “1” CHECKING THE COOLANT LEVEL
• Adapter “2” 1. Stand the vehicle on a level surface.
Oil pressure gauge set TIP
90890-03120 • Place the vehicle on the centerstand.
Oil pressure adapter B • Make sure the vehicle is upright.
90890-03124 2. Check:
Pressure gauge
• Coolant level
90890-03153
Pressure gauge The coolant level should be between the
YU-03153 maximum level mark “a” and minimum level
mark “b”.
Below the minimum level mark  Remove
the left footboard mat, coolant reservoir cap
access panel “1”, and coolant reservoir cap,
and then add the recommended coolant to
the proper level.
1 2
a
5. Measure: b
• Engine oil pressure
(at the following conditions)
Oil pressure
120.0 kPa/1200 r/min (1.20
kgf/cm²/1200 r/min, 17.4
psi/1200 r/min)

Engine oil pressure Possible causes
• Faulty oil pump

• Clogged oil filter
Below specification • Leaking oil passage 1
• Broken or damaged
oil seal
ECA13470
• Leaking oil passage NOTICE
Above specification • Faulty oil filter
• Oil viscosity too high • Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant check, and if nec-
3-30
essary, correct the antifreeze concentra-

tion of the coolant.
• Use only distilled water. However, if dis- 11
tilled water is not available, soft water may
be used. 9 10
12
3. Start the engine, warm it up for several min-
utes, and then turn it off.
4. Check:
13
• Coolant level
TIP
Before checking the coolant level, wait a few 3
7 4
minutes until it settles.
6
EAS30812
5 2
CHECKING THE COOLING SYSTEM 8
1. Remove:
• Side panel
• Bottom center cowling 1
4-1. 3. Install:
• Center cover • Fuel tank
• Fuel tank cover assembly Refer to “FUEL TANK” on page 7-1.
• Side cover • Footboard
• Footboard • Side cover
Refer to “GENERAL CHASSIS (2)” on page • Fuel tank cover assembly
4-11. • Center cover
• Fuel tank Refer to “GENERAL CHASSIS (2)” on page
Refer to “FUEL TANK” on page 7-1. 4-11.
2. Check: • Bottom center cowling
• Radiator “1” • Side panel
• Radiator inlet hose “2” • Bottom side cowling
• Radiator outlet hose “3” Refer to “GENERAL CHASSIS (1)” on page
• Radiator filler pipe “4” 4-1.
• Radiator filler hose “5”
EAS30813
• Oil cooler inlet hose “6” CHANGING THE COOLANT
• Oil cooler outlet hose “7” 1. Remove:
• Oil cooler “8” • Bottom side cowling
• Thermostat outlet hose “9” • Side panel
• Coolant pipe “10” • Bottom center cowling
• Water pump “11” Refer to “GENERAL CHASSIS (1)” on page
• Water pump inlet pipe “12” 4-1.
• Water pump outlet pipe “13” • Center cover
Cracks/damage  Replace. • Fuel tank cover assembly
Refer to “RADIATOR” on page 6-1, “THER- • Side cover
MOSTAT” on page 6-7 and “WATER PUMP” • Footboard
on page 6-9. Refer to “GENERAL CHASSIS (2)” on page
4-11.
2. Disconnect:
• Coolant reservoir hose “1”
3-31
1 1
3. Drain: 6. Drain:
• Coolant • Coolant
(from the coolant reservoir) (from the engine and radiator)
4. Remove: 7. Install:
• Radiator cap “1” • Coolant drain bolt
EWA13030
(along with the O-ring New )
WARNING
A hot radiator is under pressure. Therefore, Coolant drain bolt
do not remove the radiator cap when the en- T.
1.6 N·m (0.16 kgf·m, 1.2 lb·ft)
R.
gine is hot. Scalding hot fluid and steam may

8. Connect:
be blown out, which could cause serious in-
• Coolant reservoir hose
jury. When the engine has cooled, open the
9. Fill:
radiator cap as follows:
• Cooling system
Place a thick rag or a towel over the radiator
(with the specified amount of the recom-
cap and slowly turn the radiator cap counter-
mended coolant)
clockwise toward the detent to allow any re-
sidual pressure to escape. When the hissing Recommended antifreeze
sound has stopped, press down on the radi- High-quality ethylene glycol anti-
ator cap and turn it counterclockwise to re- freeze containing corrosion inhibi-
move. tors for aluminum engines
Mixing ratio
TIP 1:1 (antifreeze:water)
When removing the radiator cap, hold the radia- Radiator (including all routes)
tor filler pipe “2”. 1.67 L (1.77 US qt, 1.47 Imp.qt)
Coolant reservoir (up to the maxi-
mum level mark)
0.25 L (0.26 US qt, 0.22 Imp.qt)
Handling notes for coolant

Coolant is potentially harmful and should be
1 handled with special care.
EWA13040
2 WARNING
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
5. Remove: tor.
• Coolant drain bolt “1” • If coolant splashes on your clothes, quickly
(along with the O-ring) wash it away with water and then with soap
and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
3-32
ECA13481 EAS31188
NOTICE REPLACING THE V-BELT

• Adding water instead of coolant lowers the 1. Remove:
antifreeze content of the coolant. If water is • Bottom side cowling
used instead of coolant, check, and if nec- • Side panel
essary, correct the antifreeze concentra- • Bottom center cowling
tion of the coolant. Refer to “GENERAL CHASSIS (1)” on page
• Use only distilled water. However, if dis- 4-1.
tilled water is not available, soft water may • Center cover
be used. • Fuel tank cover assembly
• If coolant comes into contact with painted • Side cover (right)
surfaces, immediately wash them with wa- • Footboard (right)
ter. Refer to “GENERAL CHASSIS (2)” on page
• Do not mix different types of antifreeze. 4-11.
• Outer V-belt case
10.Install: Refer to “V-BELT AUTOMATIC TRANSMIS-
• Radiator cap SION” on page 5-34.
11.Fill: 2. Check:
• Coolant reservoir • V-belt
(with the recommended coolant to the maxi- Cracks/damage/wear  Replace.
mum level mark “a”) Grease/oil  Clean the primary and second-
ary pulleys.
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
TIP
Replace the V-belt every 20000 km (12000 mi)
of operation.
a 3. Install:
• Outer V-belt case
SION” on page 5-34.
12.Install: • Footboard (right)
• Coolant reservoir cap • Side cover (right)
13.Start the engine, warm it up for several min- • Fuel tank cover assembly
utes, and then stop it. • Center cover
14.Check: Refer to “GENERAL CHASSIS (2)” on page
• Coolant level 4-11.
Refer to “CHECKING THE COOLANT LEV- • Bottom center cowling
EL” on page 3-30. • Side panel
TIP • Bottom side cowling
Before checking the coolant level, wait a few Refer to “GENERAL CHASSIS (1)” on page
minutes until the coolant has settled. 4-1.
15.Install: EAS30658
• Footboard CHECKING THE BRAKE LIGHT SWITCHES

• Side cover 1. Check:
• Fuel tank cover assembly • Front brake light switch operation
• Center cover • Rear brake light switch operation
Refer to “GENERAL CHASSIS (2)” on page When operating the brake lever, confirm that
4-11. the brake light comes on.
• Bottom center cowling Faulty  Refer to “CHECKING THE
• Side panel SWITCHES” on page 8-221.
4-1.
3-33
EAS31147
CHECKING AND LUBRICATING THE Throttle grip free play

CABLES 1.0–3.0 mm (0.04–0.12 in)
The following procedure applies to all of the in-
ner and outer cables.
EWA13270
WARNING
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re- a
place damaged outer cable and inner cables
as soon as possible.
1. Check:
• Outer cable
Damage  Replace.
2. Check: 4. Adjust:
• Cable operation • Throttle grip free play
Rough movement  Lubricate. TIP
Prior to adjusting the throttle grip free play, throt-
Recommended lubricant tle body synchronization should be adjusted
Engine oil or a suitable cable lu-
properly.
bricant
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
TIP a. Slide back the rubber cover “1”.
Hold the cable end upright and pour a few drops b. Loosen the locknut “2”.
of lubricant into the cable sheath or use a suit- c. Turn the adjusting nut “3” in direction “a” or “b”
able lubricating device. until the specified throttle grip free play is ob-
tained.
EAS30815
CHECKING THE THROTTLE GRIP Direction “a”

1. Check: Throttle grip free play is increased.
• Throttle cables Direction “b”
Damage/deterioration  Replace. Throttle grip free play is decreased.
• Throttle cable installation
Incorrect  Reinstall the throttle cables.
Refer to “HANDLEBAR” on page 4-79.
2. Check:
• Throttle grip movement
Rough movement  Lubricate or replace the
defective part(s). 1
a
Suitable cable lubricant
3 b
2
TIP
With the engine stopped, turn the throttle grip d. Tighten the locknut.
slowly and release it. Make sure that the throttle
Throttle cable adjusting locknut
grip turns smoothly and returns properly when
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
released.
T.
R.
Repeat this check with the handlebar turned all e. Slide the rubber cover to its original position.
the way to the left and right. TIP
3. Check: Make sure that the adjusting nut is covered com-
• Throttle grip free play “a” pletely by the rubber cover.
Out of specification  Adjust. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-34
EAS30816
Right headlight
CHECKING AND CHARGING THE BATTERY
Refer to “CHECKING AND CHARGING THE Direction “a”
BATTERY” on page 8-230. Headlight beam moves to the left.
EAS30662
Direction “b”
CHECKING THE FUSES Headlight beam moves to the right.
Refer to “CHECKING THE FUSES” on page
8-229.
EAS30664
ADJUSTING THE HEADLIGHT BEAMS

1. Adjust:
• Headlight beam (vertically) 1 b a 1 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ b 2
a
a. Turn the adjusting screw “1” in direction “a” or
“b”.
b a
TIP 2
Other than the socket wrench, the adjusting
screws can be turned with a screwdriver (Phillips ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
No. 2) “2” as shown in the illustration.
Direction “a”
Headlight beam is raised.
Direction “b”
Headlight beam is lowered.
1 1
b 1 a
2 b
a
b a
2 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• Headlight beam (horizontally)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “1” in direction “a” or
“b”.
TIP
Other than the socket wrench, the adjusting
screws can be turned with a screwdriver (Phillips
No. 2) “2” as shown in the illustration.
Left headlight
Direction “a”
Headlight beam moves to the right.
Direction “b”
Headlight beam moves to the left.
3-35
3-36
CHASSIS
GENERAL CHASSIS (1) ..................................................................................4-1

ADJUSTING THE WINDSHIELD HEIGHT (for XP530E-A/XP530-A) ........4-7
1
REMOVING THE FRONT COVER.............................................................4-7
REMOVING THE SIDE PANEL..................................................................4-8
INSTALLING THE SIDE PANEL ................................................................4-8
REMOVING THE INNER PANEL...............................................................4-9
REMOVING THE BATTERY COVER ......................................................4-10
GENERAL CHASSIS (2) ................................................................................4-11

REMOVING THE SIDE COVER...............................................................4-15
2
REMOVING THE FOOTBOARD ..............................................................4-15
REMOVING THE REAR COVER .............................................................4-15
3
REMOVING THE REAR COWLING.........................................................4-16
GENERAL CHASSIS (3) ................................................................................4-17

INSTALLING THE WINDSHIELD DRIVE UNIT (for XP530D-A)..............4-21
FRONT WHEEL..............................................................................................4-22
REMOVING THE FRONT WHEEL...........................................................4-24
4
DISASSEMBLING THE FRONT WHEEL.................................................4-24
CHECKING THE FRONT WHEEL ...........................................................4-24
5
ASSEMBLING THE FRONT WHEEL.......................................................4-25
MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR
ROTOR....................................................................................................4-26
ADJUSTING THE FRONT WHEEL STATIC BALANCE ..........................4-27
INSTALLING THE FRONT WHEEL (DISC BRAKE) ................................4-28
REAR WHEEL ................................................................................................4-31

REMOVING THE REAR WHEEL .............................................................4-34
6
DISASSEMBLING THE REAR WHEEL ...................................................4-34
CHECKING THE REAR WHEEL..............................................................4-35
7
CHECKING THE REAR WHEEL DRIVE HUB .........................................4-35
CHECKING AND REPLACING THE REAR WHEEL PULLEY ................4-35
ASSEMBLING THE REAR WHEEL .........................................................4-35
MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR
ROTOR....................................................................................................4-36
ADJUSTING THE REAR WHEEL STATIC BALANCE.............................4-36
INSTALLING THE REAR WHEEL (DISC BRAKE) ..................................4-36
8
FRONT BRAKE ..............................................................................................4-40
INTRODUCTION ......................................................................................4-45
9
CHECKING THE FRONT BRAKE DISCS................................................4-45
REPLACING THE FRONT BRAKE PADS ...............................................4-46
REMOVING THE FRONT BRAKE CALIPERS ........................................4-47
DISASSEMBLING THE FRONT BRAKE CALIPERS...............................4-48
CHECKING THE FRONT BRAKE CALIPERS .........................................4-48
ASSEMBLING THE FRONT BRAKE CALIPERS.....................................4-48
INSTALLING THE FRONT BRAKE CALIPERS .......................................4-49
REMOVING THE FRONT BRAKE MASTER CYLINDER ........................4-50
CHECKING THE FRONT BRAKE MASTER CYLINDER.........................4-50
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ....................4-50
INSTALLING THE FRONT BRAKE MASTER CYLINDER.......................4-50
REAR BRAKE ................................................................................................4-53

INTRODUCTION ......................................................................................4-61
CHECKING THE REAR BRAKE DISC.....................................................4-61
REPLACING THE REAR BRAKE PADS..................................................4-61
REMOVING THE REAR BRAKE CALIPER .............................................4-62
DISASSEMBLING THE REAR BRAKE CALIPER ...................................4-63
CHECKING THE REAR BRAKE CALIPER..............................................4-63
ASSEMBLING THE REAR BRAKE CALIPER .........................................4-64
INSTALLING THE REAR BRAKE CALIPER............................................4-64
REMOVING THE REAR BRAKE MASTER CYLINDER ..........................4-65
CHECKING THE REAR BRAKE MASTER CYLINDER ...........................4-65
ASSEMBLING THE REAR BRAKE MASTER CYLINDER.......................4-65
INSTALLING THE REAR BRAKE MASTER CYLINDER .........................4-65
REPLACING THE REAR BRAKE LOCK PADS.......................................4-67
REPLACING THE REAR BRAKE LOCK CABLE.....................................4-68
REMOVING THE REAR BRAKE LOCK CALIPER ..................................4-68
CHECKING THE REAR BRAKE LOCK CALIPER ...................................4-69
ASSEMBLING THE REAR BRAKE LOCK CALIPER...............................4-69
INSTALLING THE REAR BRAKE LOCK CALIPER .................................4-70
ABS (Anti-lock Brake System) .....................................................................4-71

ABS COMPONENTS CHART ..................................................................4-72
REMOVING THE HYDRAULIC UNIT ASSEMBLY ..................................4-73
CHECKING THE HYDRAULIC UNIT ASSEMBLY...................................4-73
INSTALLING THE HYDRAULIC UNIT ASSEMBLY.................................4-74
HYDRAULIC UNIT OPERATION TEST ...................................................4-75
CHECKING THE ABS WARNING LIGHT ................................................4-78
HANDLEBAR .................................................................................................4-79
REMOVING THE HANDLEBAR...............................................................4-83
CHECKING THE HANDLEBAR ...............................................................4-83
INSTALLING THE HANDLEBAR .............................................................4-83
ADJUSTING THE ACCELERATOR POSITION SENSOR.......................4-85
FRONT FORK.................................................................................................4-87
REMOVING THE FRONT FORK LEGS...................................................4-89
DISASSEMBLING THE FRONT FORK LEGS .........................................4-89
CHECKING THE FRONT FORK LEGS ...................................................4-90
ASSEMBLING THE FRONT FORK LEGS ...............................................4-91
INSTALLING THE FRONT FORK LEGS .................................................4-95
STEERING HEAD...........................................................................................4-96
REMOVING THE LOWER BRACKET......................................................4-98
CHECKING THE STEERING HEAD ........................................................4-98
INSTALLING THE STEERING HEAD ......................................................4-99
BELT DRIVE .................................................................................................4-100

CHECKING THE DRIVE BELT ..............................................................4-101
INSTALLING THE DRIVE BELT AND DRIVE PULLEY .........................4-101
REAR SHOCK ABSORBER ASSEMBLY....................................................4-102

HANDLING THE REAR SHOCK ABSORBER .......................................4-103
DISPOSING OF A REAR SHOCK ABSORBER ....................................4-103
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY..................4-103
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ..................4-104
CHECKING THE CONNECTING ARM AND RELAY ARM....................4-104
ASSEMBLING THE CONNECTING ARM..............................................4-104
INSTALLING THE RELAY ARM.............................................................4-104
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ................4-105
SWINGARM..................................................................................................4-106
REMOVING THE SWINGARM...............................................................4-108
CHECKING THE SWINGARM ...............................................................4-108
INSTALLING THE SWINGARM .............................................................4-108
GENERAL CHASSIS (1)
EAS20026
GENERAL CHASSIS (1)

Removing the windshield and meter assembly (for XP530E-A/XP530-A)
1.6 N・m (0.16 kgf・m, 1.2 lb・ft) 2 1.3 N・m (0.13 kgf・m, 0.95 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)
1 1
7
9
8
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)

3
4.0 N・m (0.40 kgf・m, 3.0 lb・ft)
5
(3)
10 N・m (1.0 kgf・m, 7.4 lb・ft)
4 1.5 N・m (0.15 kgf・m, 1.1 lb・ft)

2.5 N・m (0.25 kgf・m, 1.8 lb・ft)
2.5 N・m (0.25 kgf・m, 1.8 lb・ft)
Order Job/Parts to remove Q’ty Remarks

1 Windshield cover 2
2 Windshield 1
3 Windshield bracket 2
4 Front cover 1
5 Windshield inner panel 1
6 Meter assembly coupler 1 Disconnect.
7 Meter panel assembly 1
8 Meter assembly 1
9 Rearview mirror 2
4-1
GENERAL CHASSIS (1)
Removing the windshield and meter assembly (for XP530D-A)

1.6 N・m (0.16 kgf・m, 1.2 lb・ft) 2 1.3 N・m (0.13 kgf・m, 0.95 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)
1 6
1
8
7
5
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
4.0 N・m (0.40 kgf・m, 3.0 lb・ft)

4
(3)
10 N・m (1.0 kgf・m, 7.4 lb・ft)
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)

3
2.5 N・m (0.25 kgf・m, 1.8 lb・ft)
2.5 N・m (0.25 kgf・m, 1.8 lb・ft)

1 Windshield cover 2
2 Windshield 1
3 Front cover 1
4 Windshield inner panel 1
5 Meter assembly coupler 1 Disconnect.
6 Meter panel assembly 1
7 Meter assembly 1
8 Rearview mirror 2
4-2
GENERAL CHASSIS (1)
Removing the front turn signal light and front cowling assembly
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
4.0 N・m (0.40 kgf・m, 3.0 lb・ft) 3
5 4
11 8
10
1
6 11
10
6
2
9
5
7
7 N・m (0.7 kgf・m, 5.2 lb・ft) 1

2
2.8 N・m (0.28 kgf・m, 2.1 lb・ft)
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
4.0 N・m (0.40 kgf・m, 3.0 lb・ft) 1.5 N・m (0.15 kgf・m, 1.1 lb・ft)

Windshield/Front cover/Windshield inner Refer to “GENERAL CHASSIS (1)” on page
panel/Rearview mirror/Bottom side cowling/Side 4-1.
panel
1 Front turn signal light coupler 2 Disconnect.
2 Front turn signal light 2
3 Headlight assembly coupler 2 Disconnect.
4 Front cowling assembly 1
5 Side cowling 2
6 Front turn signal light bracket 2
7 Headlight under panel 1
8 Headlight sub-wire harness 1
9 Headlight 1
10 Plate 2
11 Rearview mirror adaptor 2
4-3
GENERAL CHASSIS (1)
Removing the bottom cowling

1
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
3 1
1
(3)
4 5
2
7 N・m (0.7 kgf・m, 5.2 lb・ft)

1 Footboard mat 4
2 Bottom side cowling 2
3 Side panel 2
4 Radiator cover 1
5 Bottom center cowling 1
4-4
GENERAL CHASSIS (1)
Removing the battery and leg shield assembly

1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
D
4.0 N・m (0.40 kgf・m, 3.0 lb・ft) FW
2
4
1 3
5
4.3 N・m (0.43 kgf・m, 3.2 lb・ft)

6 7
10 8
9
12
9 11
4.0 N・m (0.40 kgf・m, 3.0 lb・ft)
2.8 N・m (0.28 kgf・m, 2.1 lb・ft)

1.5 N・m (0.15 kgf・m, 1.1 lb・ft)

panel/Meter assembly/Rearview mirror/Bottom 4-1.
side cowling/Side panel/Front cowling assembly
cover/Footboard 4-11.
1 Battery cover 1
2 Negative battery lead 1 Disconnect.
3 Positive battery lead 1 Disconnect.
4 Battery band 1
5 Battery 1
6 Storage compartment lid lock solenoid coupler 1 Disconnect. (for XP530-A/XP530D-A)
7 Remote control unit coupler 1 Disconnect.
8 Auxiliary DC jack coupler 1 Disconnect.
9 Inner panel 2
10 Leg shield assembly 1
11 Band 1
12 Remote control unit 1
4-5
GENERAL CHASSIS (1)
Removing the battery and leg shield assembly

1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
D
4.0 N・m (0.40 kgf・m, 3.0 lb・ft) FW
15
16
4.3 N・m (0.43 kgf・m, 3.2 lb・ft)
17
13
14
4.0 N・m (0.40 kgf・m, 3.0 lb・ft)
2.8 N・m (0.28 kgf・m, 2.1 lb・ft)

1.5 N・m (0.15 kgf・m, 1.1 lb・ft)

13 Auxiliary DC jack 1
14 Storage box 1
15 Protector 1
16 Storage compartment lid lock solenoid 1
17 Cover 1
4-6
GENERAL CHASSIS (1)
EAS31397
ADJUSTING THE WINDSHIELD HEIGHT (for

XP530E-A/XP530-A)
1. Adjust: 1
• Windshield height
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the windshield covers “1” by remov-
ing the quick fasteners “2”.
1
2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31398
REMOVING THE FRONT COVER

1. Remove:
• Front cover “1”
2
b. Remove the windshield by removing the

screws “3”. 1
3 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the front cover bolts “2”.
c. Install the windshield to the desired position

by installing the screws “3”. 2
2
3
b. Remove the front cover bolt “3”.
d. Tighten the screws to the specified torque.

3
Windshield screw
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
e. Place the windshield covers “1”, and then in-

stall the quick fasteners.
c. Remove the front cover “1” by sliding it for-

ward.
4-7
GENERAL CHASSIS (1)
TIP
Remove projections “a” on the front cover from
grommets “b”.
1 4
b
a 3
c. Remove the side panel “1”.

TIP
Remove the side panel by removing the lower
part “a” and upper part “b”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30821
REMOVING THE SIDE PANEL b

The following procedure applies to both of the
side panels.
1. Remove:
2. Remove:
• Side panel “1”
a
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the side panel screws “2”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30822
2 INSTALLING THE SIDE PANEL
side panels.
1. Install:
• Side panel “1”
b. Remove the quick fasteners “3” and the side

panel bolt “4”.
4-8
GENERAL CHASSIS (1)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the side panel “1”.
4
TIP
Install the side panel by installing the lower part
“a” and upper part “b”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
EAS30819
REMOVING THE INNER PANEL

1 The following procedure applies to both of the in-
ner panels.
1. Remove:
• Inner panel “1”
b. Install the side panel bolt “2” and the quick

fasteners “3”.
1
Side panel bolt
1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
T.
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the part “a” of the inner panel and
slide the inner panel “1” to the upper side.
TIP
When removing the part “a”of the inner panel,
2
use a commercially available cover removal tool
“b”.
a
c. Install the side panel screws “4”.
Side panel screw
1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
T.
R.
4-9
GENERAL CHASSIS (1)
a
a
b. Remove the inner panel “1” by moving it in ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

the arrow direction.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31677
REMOVING THE BATTERY COVER

1. Remove:
• Battery cover “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the battery cover screw “2”.
b. Remove the part “a” of the battery cover.
c. Remove the battery cover “1” by sliding it to
the upper side.
4-10
GENERAL CHASSIS (2)
EAS20155
GENERAL CHASSIS (2)

Removing the footboard
7 FW
D
8 9
1 2
10
4
5
9 6
3
6
3.8 N・m (0.38 kgf・m, 2.8 lb・ft)
4.0 N・m (0.40 kgf・m, 3.0 lb・ft)
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
4.0 N・m (0.40 kgf・m, 3.0 lb・ft)

Bottom side cowling/Side panel/Bottom center Refer to “GENERAL CHASSIS (1)” on page
cowling 4-1.
1 Center cover 1
2 Fuel tank cover assembly 1
3 Seat/fuel lid lock solenoid coupler 1 Disconnect.
4 Seat lock cable 1 Disconnect.
5 Side cover 2
6 Footboard 4
7 Cover 1
8 Seat/fuel lid lock solenoid 1
9 Cover 2
10 Fuel tank cover 1
4-11
GENERAL CHASSIS (2)
Removing the rear cowling and mudguard assembly

22 N・m (2.2 kgf・m, 16 lb・ft) 1 7
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)

10 N・m (1.0 kgf・m, 7.4 lb・ft)
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
22 N・m (2.2 kgf・m, 16 lb・ft)
4 5
5 4
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)

cowling 4-1.
1 Cover 1
2 Rear cover 1
3 Grab bar 2
4 Rear cowling 2
5 Rear turn signal light coupler 2 Disconnect.
6 License plate light connector 2 Disconnect.
7 Mudguard assembly 1
4-12
GENERAL CHASSIS (2)
Removing the rear cowling assembly and seat assembly

1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
3.8 N・m (0.38 kgf・m, 2.8 lb・ft)
7 N・m (0.7 kgf・m, 5.2 lb・ft) 6

1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
5 6
3 7
9 1
8
3.8 N・m (0.38 kgf・m, 2.8 lb・ft)

4.0 N・m (0.40 kgf・m, 3.0 lb・ft)

cowling 4-1.
cover/Footboard/Rear cowling/Mudguard 4-11.
assembly
1 Rear cowling assembly 1
2 Seat lock cable 1 Disconnect.
3 Tail/brake light coupler 2 Disconnect.
4 Seat heater coupler 1 Disconnect. (for XP530D-A)
5 Seat assembly 1
6 Tail/brake light 2
7 Lid 1
8 Seat lock key cylinder 1
9 Tail/brake light cover 1
4-13
GENERAL CHASSIS (2)
Removing the storage box

0.7 N・m (0.07 kgf・m, 0.52 lb・ft) 16 N・m (1.6 kgf・m, 12 lb・ft)
9
2
7
8
32 N・m (3.2 kgf・m, 24 lb・ft)
10
16 N・m (1.6 kgf・m, 12 lb・ft)
6
10
1 11 3
6
4
23 N・m (2.3 kgf・m, 17 lb・ft)

12
7 N・m (0.7 kgf・m, 5.2 lb・ft)

cowling 4-1.
Center cover/Fuel tank cover assembly/Side
cover/Footboard/Rear cowling/Mudguard Refer to “GENERAL CHASSIS (2)” on page
assembly/Rear cowling assembly/Seat assem- 4-11.
bly
1 Storage box inner mat 1
2 Storage box light switch coupler 1 Disconnect.
3 Storage box light connector 2 Disconnect.
4 Wire harness 1
5 Storage box 1
6 Rear panel 2
7 Bracket 1
8 Seat hinge assembly 1
9 Storage box light switch 1
10 Stopper 2
11 Storage box light 1
12 Seat lock assembly 1
4-14
GENERAL CHASSIS (2)
EAS31519
REMOVING THE SIDE COVER 4-1.
The following procedure applies to both of the • Center cover
side covers. • Side cover
1. Remove: 2. Remove:
• Side cover “1” • Footboard “1”
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the side cover bolts “2” and the a. Remove the footboard bolt, screw, and quick
quick fastener “3”. fastener.
2 b. Remove the footboard “1” by sliding it to the
3 upper side.
2
b. Remove the side cover “1”.

TIP 1
Remove projections “a” on the side cover from ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
grommets “b”.
EAS31193
REMOVING THE REAR COVER

1 1. Remove:
• Cover “1”
b
a 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31523
REMOVING THE FOOTBOARD

The following procedure applies to both of the 2. Remove:
footboards. • Rear cover “1”
1. Remove:
• Side panel
4-15
GENERAL CHASSIS (2)
b. Remove the rear cowling “1” by sliding it rear-

ward.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the quick fasteners “2”.
b. Remove the rear cover “1” by sliding it rear- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ward.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31841
REMOVING THE REAR COWLING

rear cowlings.
1. Remove:
• Side cover
4-11.
• Cover
• Rear cover
• Grab bar
2. Remove:
• Rear cowling “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the rear cowling screw, bolt, and
quick fastener.
4-16
GENERAL CHASSIS (3)
EAS20156
GENERAL CHASSIS (3)

Removing the battery box and ECU (Engine Control Unit)
32 N・m (3.2 kgf・m, 24 lb・ft)
1.8 N・m (0.18 kgf・m, 1.3 lb・ft)

5
11
4
LT 9 8
10
43 N・m (4.3 kgf・m, 32 lb・ft)
3
1 2
7 N・m (0.7 kgf・m, 5.2 lb・ft)

Windshield/Front cover/Windshield inner
panel/Meter assembly/Rearview mirror/Bottom Refer to “GENERAL CHASSIS (1)” on page
side cowling/Side panel/Front cowling assem- 4-1.
bly/Leg shield assembly/Battery
1 Ignition coil connector 2 Disconnect.
2 Ignition coil 1
3 Buzzer coupler 1 Disconnect.
4 Intake air temperature sensor coupler 1 Disconnect.
5 ECU coupler 2 Disconnect.
6 Wire harness 1
7 Battery box 1
8 Battery band 1
9 ECU (Engine Control Unit) 1
10 Buzzer 1
11 Intake air temperature sensor 1
4-17
GENERAL CHASSIS (3)
Removing the electrical components tray (for XP530E-A/XP530-A)

7
8
8
10 N・m (1.0 kgf・m, 7.4 lb・ft)
8 N・m (0.8 kgf・m, 5.9 lb・ft)
18 N・m (1.8 kgf・m, 13 lb・ft)
7 N・m (0.7 kgf・m, 5.2 lb・ft)
2
10 N・m (1.0 kgf・m, 7.4 lb・ft)
4 6
3 1 FW
D
bly/Leg shield assembly
1 Handlebar switch coupler 2
2 Rectifier/regulator coupler 1 Disconnect.
3 Wire harness 1
4 Rear brake hose 1
5 Rectifier/regulator 1
6 Electrical components tray 1
7 Meter bracket 1
8 Windshield bracket 2
4-18
GENERAL CHASSIS (3)
Removing the electrical components tray (for XP530D-A)
10 N・m (1.0 kgf・m, 7.4 lb・ft)
18 N・m (1.8 kgf・m, 13 lb・ft)

8
8 N・m (0.8 kgf・m, 5.9 lb・ft)
7 N・m (0.7 kgf・m, 5.2 lb・ft)

6
10 N・m (1.0 kgf・m, 7.4 lb・ft)
8 N・m (0.8 kgf・m, 5.9 lb・ft)
2
5 9
4
3 1 FW
D

Brake hose holder Refer to “HANDLEBAR” on page 4-79.
1 Handlebar switch coupler 2
2 Rectifier/regulator coupler 1 Disconnect.
3 Windshield drive unit coupler 1 Disconnect.
4 Wire harness 1
5 Rear brake hose 1
6 Rectifier/regulator 1
7 Meter bracket 1
8 Windshield drive unit 1
9 Electrical components tray 1
4-19
GENERAL CHASSIS (3)
Removing the headlight stay
15 N・m (1.5 kgf・m, 11 lb・ft)
35 N・m (3.5 kgf・m, 26 lb・ft) 4
5 9
2
LT
6 7
LT
8
4
1
7 N・m (0.7 kgf・m, 5.2 lb・ft)
18 N・m (1.8 kgf・m, 13 lb・ft)

FW
D

Battery box/Electrical components tray/Meter Refer to “GENERAL CHASSIS (3)” on page
bracket/Windshield bracket (XP530E-A/XP530- 4-17.
A)/Windshield drive unit (XP530D-A)
Refer to “ABS (Anti-lock Brake System)” on
Hydraulic unit page 4-71.
1 Brake hose holder 1
2 Wire harness 1
3 Clamp 2
4 Cover 2
5 Plate 1
6 Headlight stay 1 1
7 Wire harness bracket 1
8 Headlight stay 2 1
9 Damper 1
4-20
GENERAL CHASSIS (3)
EAS31850
INSTALLING THE WINDSHIELD DRIVE UNIT

(for XP530D-A)
1. Check:
• Windshield drive unit operation
TIP
After installing the windshield drive unit to the
headlight stay, check the operation of the drive
unit.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the windshield drive unit “1”, and then
connect the windshield drive unit coupler to
the wire harness.
b. Operate the windshield drive unit and check
that the windshield drive unit arms can be
moved fully up and down within the specified
operation time.
Specified operation time (time re-
quired to move up or down)
1.9–3.8 seconds
1 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-21
FRONT WHEEL
EAS20028
FRONT WHEEL
Removing the front wheel and brake discs
7 N・m (0.7 kgf・m, 5.2 lb・ft) 35 N・m (3.5 kgf・m, 26 lb・ft)

3
3
2
1
2.5 N・m (0.25 kgf・m, 1.8 lb・ft)
5 35 N・m (3.5 kgf・m, 26 lb・ft)
91 N・m (9.1 kgf・m, 67 lb・ft)
3
LT
8
11 21 N・m (2.1 kgf・m, 15 lb・ft)

5
3
6
6
7
4
1 2
12 7 N・m (0.7 kgf・m, 5.2 lb・ft)
2.5 N・m (0.25 kgf・m, 1.8 lb・ft)
9 9 N・m (0.9 kgf・m, 6.6 lb・ft)
10
12
23 N・m (2.3 kgf・m, 17 lb・ft)
LT
23 N・m (2.3 kgf・m, 17 lb・ft)

1 Reflector bracket 2
2 Front reflector 2
3 Front brake hose holder 4
4 Front wheel sensor 1
5 Front brake caliper 2
6 Front wheel axle pinch bolt 4 Loosen.
7 Front wheel axle bolt 1
8 Front wheel axle 1
9 Front wheel 1
10 Collar 1 Length: 22 mm (0.87 in)
11 Collar 1 Length: 18 mm (0.71 in)
12 Front brake disc 2
4-22
FRONT WHEEL
Disassembling the front wheel
2.0 N・m (0.20 kgf・m, 1.5 lb・ft)
2
3 3.0 N・m (0.30 kgf・m, 2.2 lb・ft)
8 N・m (0.8 kgf・m, 5.9 lb・ft)
LT
3
2

1 Front wheel sensor rotor 1
2 Oil seal 2
3 Wheel bearing 2
4 Collar 1
4-23
FRONT WHEEL
EAS30145
ject it to shocks.
REMOVING THE FRONT WHEEL • If any solvent gets on the wheel sensor ro-
ECA21380
NOTICE tor, wipe it off immediately.

Keep magnets (including magnetic pick-up 1. Remove:
tools, magnetic screwdrivers, etc.) away • Oil seals
from the front wheel sensor “1”, otherwise • Wheel bearings
the wheel sensor may be damaged, resulting ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
in improper performance of the ABS. a. Clean the surface of the front wheel hub.
b. Remove the oil seals “1” with a flat-head
screwdriver.
TIP
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel surface.

EWA13120
WARNING
2. Remove: c. Remove the wheel bearings “3” with a gener-
• Front brake caliper (left) al bearing puller.
• Front brake caliper (right)
• Front wheel sensor
ECA21440
NOTICE
• Do not apply the brake lever when remov-
ing the brake calipers.
• Be sure not to contact the sensor electrode
to any metal part when removing the front
wheel sensor from the sensor housing.
3. Elevate:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Front wheel
TIP EAS30147
Place the vehicle on a maintenance stand so CHECKING THE FRONT WHEEL
that the front wheel is elevated. 1. Check:
4. Loosen: • Wheel axle
• Wheel axle pinch bolt Roll the wheel axle on a flat surface.
5. Remove: Bends  Replace.
EWA13460
• Front wheel axle bolt WARNING
• Front wheel axle
• Front wheel Do not attempt to straighten a bent wheel ax-
le.
EAS30146
DISASSEMBLING THE FRONT WHEEL

ECA21340
NOTICE
• Do not drop the wheel sensor rotor or sub-
4-24
FRONT WHEEL
EAS30151
ASSEMBLING THE FRONT WHEEL

ECA21340
NOTICE
ject it to shocks.
• If any solvent gets on the wheel sensor ro-
tor, wipe it off immediately.
1. Install:
• Wheel bearings New
2. Check: • Oil seals New
• Tire ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Front wheel a. Install the new wheel bearing (right side).
Damage/wear  Replace. ECA18110
NOTICE
Refer to “CHECKING THE TIRES” on page
3-19 and “CHECKING THE WHEELS” on Do not contact the wheel bearing inner race
page 3-19. “1” or balls “2”. Contact should be made
3. Measure: only with the outer race “3”.
• Radial wheel runout “1” TIP
• Lateral wheel runout “2” Use a socket “4” that matches the diameter of
Over the specified limits  Replace. the wheel bearing outer race.
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
b. Install the spacer.

c. Install the new wheel bearing (left side).
TIP
Place a suitable washer “1” between the socket
4. Check: “2” and the bearing so that both the inner race
• Wheel bearings “3” and outer race “4” are pressed at the same
Front wheel turns roughly or is loose  Re- time, and then press the bearing until the inner
place the wheel bearings. race makes contact with the spacer “5”.
• Oil seals
Damage/wear  Replace.
4-25
FRONT WHEEL
d. Install the new oil seals.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install: 1
• Front wheel sensor rotor
Wheel sensor rotor bolt
8 N·m (0.8 kgf·m, 5.9 lb·ft) 2
T.
LOCTITE®
R.
ECA17200
NOTICE
Replace the wheel sensor rotor bolts with
new ones.
TIP
Install the wheel sensor rotor with the stamped
mark “1” facing outward.
a. 45–55
A
A. Wheel rotation direction
B. Left side
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Measure:
3. Install: • Wheel sensor rotor runout
• Air valve Out of specification  Correct the wheel sen-
TIP sor rotor runout or replace the wheel sensor
• Fasten air valve nut “1” and tighten air valve rotor.
locknut “2” to 3.0 N·m (0.30 kgf·m, 2.2 lb·ft). Refer to “MAINTENANCE OF THE FRONT
• When installing the air valve, orient the air WHEEL SENSOR AND SENSOR ROTOR”
valve referring to the illustration. on page 4-26.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Wheel sensor rotor runout limit
a. Tighten the air valve nut “1”. 0.25 mm (0.01 in)
Front wheel air valve nut EAS30155
2.0 N·m (0.20 kgf·m, 1.5 lb·ft) MAINTENANCE OF THE FRONT WHEEL
T.
SENSOR AND SENSOR ROTOR

R.
b. Tighten the air valve locknut “2” while holding ECA21070
the air valve nut so as not to turn the nut. NOTICE

• Handle the ABS components with care
Front wheel air valve locknut since they have been accurately adjusted.
3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
Keep them away from dirt and do not sub-
T.
R.
ject them to shocks.

• The front wheel sensor cannot be disas-
sembled. Do not attempt to disassemble it.
If faulty, replace with a new one.
• Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers,
etc.) away from the front wheel sensor or
front wheel sensor rotor.
4-26
FRONT WHEEL
• Do not drop or shock the wheel sensor or

the wheel sensor rotor.
1. Check:
• Front wheel sensor “1”
Cracks/bends/distortion  Replace.
Iron powder/dust  Clean.
2. Check:
• Front wheel sensor rotor “1”
Cracks/damage/scratches  Replace the
front wheel sensor rotor.
Iron powder/dust/solvent  Clean.
c. If the runout is above specification, remove
TIP the sensor rotor from the wheel, rotate it by
• The wheel sensor rotor is installed on the inner
two or three bolt holes, and then install it.
side of the wheel hub.
• When cleaning the wheel sensor rotor, be Wheel sensor rotor bolt
careful not to damage the surface of the sensor 8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
rotor. LOCTITE®
R.
ECA17200
1 NOTICE
Replace the wheel sensor rotor bolts with
new ones.
d. If the runout is still above specification, re-
place the wheel sensor rotor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30152
ADJUSTING THE FRONT WHEEL STATIC

3. Measure: BALANCE
• Wheel sensor rotor runout TIP
Out of specification  Clean the installation • After replacing the tire, wheel or both, the front
surface of the wheel sensor rotor and correct wheel static balance should be adjusted.
the wheel sensor rotor runout, or replace the • Adjust the front wheel static balance with the
wheel sensor rotor. brake disc installed.
Wheel sensor rotor runout limit 1. Remove:

0.25 mm (0.01 in) • Balancing weight(s)
2. Find:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Front wheel’s heavy spot
a. Hold the dial gauge at a right angle against TIP
the wheel sensor rotor surface. Place the front wheel on a maintenance balanc-
b. Measure the wheel sensor rotor runout. ing stand.
4-27
FRONT WHEEL
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ b. Turn the front wheel 90 so that the heavy

a. Spin the front wheel. spot is positioned as shown.
b. When the front wheel stops, put an “X1” mark
at the bottom of the wheel.
c. If the heavy spot does not stay in that posi-

tion, install a heavier weight.
c. Turn the front wheel 90 so that the “X1” mark d. Repeat steps (b) and (c) until the front wheel
is positioned as shown. is balanced.
d. Release the front wheel. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
e. When the wheel stops, put an “X2” mark at 4. Check:
the bottom of the wheel. • Front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure it stays at
each position shown.
f. Repeat steps (c) through (e) several times

until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest is b. If the front wheel does not remain stationary
the front wheel’s heavy spot “X”. at all of the positions, rebalance it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
• Front wheel static balance EAS30154
INSTALLING THE FRONT WHEEL (DISC

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
BRAKE)
a. Install a balancing weight “1” onto the rim ex-
1. Install:
actly opposite the heavy spot “X”.
• Front brake discs
TIP
Start with the lightest weight. Front brake disc bolt
23 N·m (2.3 kgf·m, 17 lb·ft)
T.
LOCTITE®
R.
ECA19150
NOTICE
Replace the brake disc bolts with new ones.
TIP
Tighten the brake disc bolts in stages and in a
crisscross pattern.
4-28
FRONT WHEEL
“3”  pinch bolt “2”  pinch bolt “3”.

c. Temporarily install the pinch bolts “4” and “5”,
and then tighten the pinch bolts to 21 N·m
(2.1 kgf·m, 15 lb·ft) in the order of pinch bolt
“5”  pinch bolt “4”  pinch bolt “5”.
2. Check: 1
• Front brake discs
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-45. 5 4 3 2
3. Lubricate:
• Oil seal lips
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Recommended lubricant 6. Install:
Lithium-soap-based grease • Front wheel sensor
4. Install: Front wheel sensor bolt
• Collar 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
• Front wheel
ECA21020
NOTICE
• Front wheel axle bolt
Make sure there are no foreign materials in
TIP
Apply lithium soap-based grease onto the mat- the front wheel sensor rotor and front wheel
ing surface of the front wheel axle bolt. sensor. Foreign materials cause damage to
the front wheel sensor rotor and front wheel
5. Tighten: sensor.
• Front wheel axle pinch bolt TIP
• When installing the front wheel sensor, check
Front wheel axle the front wheel sensor lead for twists.
91 N·m (9.1 kgf·m, 67 lb·ft) • To route the front wheel sensor lead, refer to
T.
Front wheel axle pinch bolt

R.
“CABLE ROUTING” on page 2-33.

21 N·m (2.1 kgf·m, 15 lb·ft)
7. Measure:
ECA19760 • Distance “a”
NOTICE (between the wheel sensor rotor “1” and front
Before tightening the wheel axle, push down wheel sensor “2”)
hard on the handlebars several times and Out of specification  Check the wheel bear-
check if the front fork rebounds smoothly. ing for looseness, and the front wheel sensor
and sensor rotor installation conditions
TIP
(warpage caused by overtorque, wrong in-
First, tighten the wheel axle, then the wheel axle
stallation direction, rotor decentering, LOC-
pinch bolt.
TITE® on the mounting surface of the rotor,
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ deformation caused by an impact during ser-
a. Insert the front wheel axle from the right side, vice and caught foreign materials). If there is
temporarily install the front wheel axle bolt “1” any defective part, repair or replace the de-
from the left side, and then tighten the front fective part.
wheel axle to 91 N·m (9.1 kgf·m, 67 lb·ft).
b. Temporarily install the pinch bolts “2” and “3”,
and then tighten the pinch bolts to 21 N·m
(2.1 kgf·m, 15 lb·ft) in the order of pinch bolt
4-29
FRONT WHEEL
Distance “a” (between the front

wheel sensor rotor and front
wheel sensor)
0.3–1.1 mm (0.01–0.04 in)
TIP
Measure the distance between the front wheel
sensor rotor and front wheel sensor in several
places in one rotation of the front wheel. Do not
turn the front wheel while the thickness gauge is
installed. This may damage the front wheel sen-
sor rotor and the front wheel sensor.
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
a
1
2
1
8. Install:
• Front brake calipers
• Front brake hose holder
Front brake caliper bolt
35 N·m (3.5 kgf·m, 26 lb·ft)
T.
Front brake hose holder bolt (left)

R.
9 N·m (0.9 kgf·m, 6.6 lb·ft)

Front brake hose holder bolt
(right)
7 N·m (0.7 kgf·m, 5.2 lb·ft)
EWA13500
WARNING
Make sure the brake hose is routed properly.
4-30
REAR WHEEL
EAS20029
REAR WHEEL
Removing the rear wheel
12 14
13
7 N・m (0.7 kgf・m, 5.2 lb・ft) 15
10 N・m (1.0 kgf・m, 7.4 lb・ft)
160 N・m (16 kgf・m, 118 lb・ft) 1
2 16
7
8
11
6 5
16 N・m (1.6 kgf・m, 12 lb・ft)

10
5 6 9
4
16 N・m (1.6 kgf・m, 12 lb・ft) 10 N・m (1.0 kgf・m, 7.4 lb・ft)

Rear brake caliper/Rear brake lock caliper Refer to “REAR BRAKE” on page 4-53.
1 Rear wheel sensor lead holder 1
2 Rear wheel sensor 1
3 Drive belt upper guard 1
4 Drive belt lower guard 1
5 Locknut 2 Loosen.
6 Adjusting bolt 2 Loosen.
7 Rear wheel axle nut 1
8 Washer 1
9 Rear wheel axle 1
10 Adjusting block (left) 1
11 Adjusting block (right) 1
12 Brake caliper bracket 1
13 Rear wheel sensor housing 1
14 Rear wheel 1
15 Collar (right) 1
16 Collar (left) 1
4-31
REAR WHEEL
Removing the rear brake disc and rear wheel pulley
30 N・m (3.0 kgf・m, 22 lb・ft)
8 N・m (0.8 kgf・m, 5.9 lb・ft)
LT
LT
1
2
10 N・m (1.0 kgf・m, 7.4 lb・ft)
LT
5 4
LT
64 N・m (6.4 kgf・m, 47 lb・ft) 3

1 Rear brake disc 1
2 Rear wheel sensor rotor 1
3 Drive belt guide 1
4 Rear wheel pulley 1
5 Rear wheel 1
4-32
REAR WHEEL
Disassembling the rear wheel assembly
1
4
2
1

1 Oil seal 2
2 Wheel bearing (left) 1
3 Collar 1
4 Wheel bearing (right) 1
4-33
REAR WHEEL
EAS30910
(left side and right side)
REMOVING THE REAR WHEEL
ECA21390
NOTICE
Keep magnets (including magnetic pick-up
1 2
tools, magnetic screwdrivers, etc.) away
from the rear wheel sensor “1”, otherwise
the wheel sensor may be damaged, resulting
in improper performance of the ABS.
4. Remove:
• Wheel axle nut “1”
• Washer
• Rear wheel axle “2”
• Rear wheel
• Rear brake caliper bracket
1 • Rear wheel sensor housing
• Collars
1. Stand the vehicle on a level surface. ECA21400
EWA13120 NOTICE
WARNING Be sure to remove the rear wheel sensor be-
Securely support the vehicle so that there is fore removing the brake caliper bracket, oth-
no danger of it falling over. erwise the sensor could be damaged.
TIP TIP
Place the vehicle on the centerstand so that the Push the rear wheel forward and remove the
rear wheel is elevated. drive belt from the rear wheel pulley.
2. Remove:
• Rear wheel sensor “1”
• Rear brake caliper “2”
• Rear brake lock caliper “3” 2
ECA25760
1
NOTICE
• Do not apply the brake lever when remov-
ing the brake caliper.
• Be sure not to contact the sensor electrode
to any metal part when removing the rear
wheel sensor from the rear brake caliper
bracket. EAS31154
DISASSEMBLING THE REAR WHEEL

ECA21340
NOTICE
3
ject it to shocks.
• If any solvent gets on the wheel sensor ro-
tor, wipe it off immediately.
1. Remove:
• Rear wheel sensor rotor
1 2 • Oil seals
• Wheel bearings
3. Loosen: Refer to “DISASSEMBLING THE FRONT
• Locknuts “1” WHEEL” on page 4-24.
• Adjusting bolts “2”
4-34
REAR WHEEL
EAS30159
c. Clean the rear wheel drive hub with a clean
CHECKING THE REAR WHEEL cloth, especially the surfaces that contact the
1. Check: pulley.
• Wheel axle d. Install the new rear wheel pulley and drive
• Wheel bearings belt guide.
• Oil seals
Refer to “CHECKING THE FRONT WHEEL” Rear wheel pulley bolt
on page 4-24. 64 N·m (6.4 kgf·m, 47 lb·ft)
T.
LOCTITE®
R.
2. Check:
• Tire Drive belt guide bolt
• Rear wheel 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Damage/wear  Replace. LOCTITE®
Refer to “CHECKING THE TIRES” on page
3-19 and “CHECKING THE WHEELS” on TIP
• Tighten the rear wheel pulley bolts in stages
page 3-19.
and in a crisscross pattern.
3. Measure:
• When tightening the drive belt guide bolts,
• Radial wheel runout
tighten the bolt at the punch mark “a” first and
• Lateral wheel runout
then other bolts in stages and in a crisscross
Refer to “CHECKING THE FRONT WHEEL”
pattern.
on page 4-24.
EAS30160
CHECKING THE REAR WHEEL DRIVE HUB

1. Check:
• Rear wheel drive hub “1”
Cracks/damage  Replace the rear wheel.
EAS30162
CHECKING AND REPLACING THE REAR

WHEEL PULLEY
1. Check:
a
• Rear wheel pulley
Surface plating has come off  Replace the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
rear wheel pulley.
Bent teeth  Replace the rear wheel pulley. EAS30163
• Drive belt guide ASSEMBLING THE REAR WHEEL

Cracks/damage/wear  Replace the drive ECA21340
belt guide. NOTICE

2. Replace: • Do not drop the wheel sensor rotor or sub-
• Rear wheel pulley ject it to shocks.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • If any solvent gets on the wheel sensor ro-
a. Remove the drive belt guide bolts and the tor, wipe it off immediately.
drive belt guide. 1. Install:
b. Remove the rear wheel pulley bolts and the • Wheel bearings New
rear wheel pulley. • Oil seal New
4-35
REAR WHEEL
Refer to “ASSEMBLING THE FRONT EAS30165
WHEEL” on page 4-25. INSTALLING THE REAR WHEEL (DISC

BRAKE)
EAS30167
1. Install:
MAINTENANCE OF THE REAR WHEEL • Rear wheel sensor rotor
SENSOR AND SENSOR ROTOR • Rear brake disc
ECA21060
NOTICE Rear wheel sensor bolt

• Handle the ABS components with care 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
since they have been accurately adjusted. Rear brake disc bolt
R.
Keep them away from dirt and do not sub- 30 N·m (3.0 kgf·m, 22 lb·ft)
ject them to shocks. LOCTITE®
• The rear wheel sensor cannot be disassem- ECA19150
bled. Do not attempt to disassemble it. If NOTICE
faulty, replace with a new one.
Replace the brake disc bolts with new ones.
• Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers, TIP
etc.) away from the rear wheel sensor or • Install the wheel sensor rotor with the stamped
rear wheel sensor rotor. mark “1” facing outward.
• Do not drop or shock the wheel sensor or • Tighten the brake disc bolts in stages and in a
the wheel sensor rotor. crisscross pattern.
1. Check:
• Rear wheel sensor
Refer to “MAINTENANCE OF THE FRONT 1
WHEEL SENSOR AND SENSOR ROTOR”
on page 4-26.
2. Check:
• Rear wheel sensor rotor C
Refer to “MAINTENANCE OF THE FRONT
on page 4-26.
3. Measure:
• Wheel sensor rotor runout
Refer to “MAINTENANCE OF THE FRONT
on page 4-26.
EAS30164
ADJUSTING THE REAR WHEEL STATIC

BALANCE
TIP
• After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted. 2. Check:
• Adjust the rear wheel static balance with the • Rear brake disc
brake disc and rear wheel pulley installed. Refer to “CHECKING THE REAR BRAKE
Adjust: DISC” on page 4-61.
• Rear wheel static balance 3. Install:
Refer to “ADJUSTING THE FRONT WHEEL • Drive belt guide
STATIC BALANCE” on page 4-27. • Rear wheel pulley
4-36
REAR WHEEL
• Fit the brake torque stop pin “a” on the swing-

Rear wheel pulley bolt arm into the slot “b” on the rear brake caliper
64 N·m (6.4 kgf·m, 47 lb·ft)
bracket.
T.
LOCTITE®
R.
Drive belt guide bolt • When installing the rear brake caliper bracket
10 N·m (1.0 kgf·m, 7.4 lb·ft) and the rear wheel sensor housing, align the
LOCTITE® projection “c” on the rear brake caliper bracket
with the slot “d” of the rear wheel sensor hous-
TIP ing.
• Tighten the rear wheel pulley bolts in stages • After installing the rear wheel to the vehicle,
and in a crisscross pattern. make sure that the projection “e” on the brake
• When tightening the drive belt guide bolts, caliper bracket and the projection “f” on the
tighten the bolt at the punch mark “a” first and rear wheel sensor housing are aligned.
then other bolts in stages and in a crisscross • Install the left adjusting block so that projection
pattern. “g” faces to the front of the vehicle.
• Install the right adjusting block so that upper
chamfer “h” faces to the top of the vehicle and
lower chamfer “h” faces to the bottom of the ve-
hicle.
a
b
4. Lubricate:
• Oil seal lips d
5. Install:
• Collars
• Rear wheel sensor housing
• Rear brake caliper bracket
• Rear wheel e
• Adjusting blocks f
• Rear wheel axle
• Washer
• Wheel axle nut
TIP
• Do not install the brake caliper and brake lock
caliper.
4-37
REAR WHEEL
Rear wheel sensor bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
g ECA21080
h NOTICE
Make sure there are no foreign materials in
the rear wheel sensor rotor and rear wheel
sensor. Foreign materials cause damage to
the rear wheel sensor rotor and rear wheel
sensor.
A. Left side TIP
B. Right side When installing the rear wheel sensor, check the
6. Install: rear wheel sensor lead for twists.
• Rear brake caliper
• Rear brake lock caliper
(temporarily)
7. Adjust:
• Drive belt tension
3-22.
8. Tighten:
• Wheel axle nut
• Rear brake caliper bolts 1
• Rear brake lock caliper bolts
TIP
Rear wheel axle nut To route the rear wheel sensor lead, refer to
160 N·m (16 kgf·m, 118 lb·ft) “CABLE ROUTING” on page 2-33.
T.
Rear brake caliper bolt

R.
27 N·m (2.7 kgf·m, 20 lb·ft) 10.Measure:

Rear brake lock caliper bolt • Distance “a”
23 N·m (2.3 kgf·m, 17 lb·ft) (between the rear wheel sensor rotor “1” and
rear wheel sensor “2”)
EWA13500
Out of specification  Check the wheel bear-
WARNING ing for looseness, and the rear wheel sensor
Make sure the brake hose is routed properly. and sensor rotor installation conditions
TIP (warpage caused by overtorque, wrong in-
When tightening the wheel axle nut, there stallation direction, rotor decentering, LOC-
should be no clearance “a” between the adjust- TITE® on the mounting surface of the rotor,
ing block “1” and adjusting bolt “2”. deformation caused by an impact during ser-
vice and caught foreign materials). If there is
any defective part, repair or replace the de-
fective part.
2 Distance “a” (between the rear

wheel sensor rotor and rear wheel
sensor)
1
a 0.5–1.4 mm (0.02–0.06 in)
TIP
Measure the distance between the rear wheel
sensor rotor and rear wheel sensor in several
9. Install: places in one rotation of the rear wheel. Do not
• Rear wheel sensor “1” turn the rear wheel while the thickness gauge is
installed. This may damage the rear wheel sen-
4-38
REAR WHEEL
sor rotor and the rear wheel sensor.
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
1
2
2
a
11.Adjust:
LOCK CABLE” on page 3-18.
4-39
FRONT BRAKE
EAS20030
FRONT BRAKE
Removing the front brake pads
35 N・m (3.5 kgf・m, 26 lb・ft)
5 N・m (0.5 kgf・m, 3.7 lb・ft)
6
10
7
9 N・m (0.9 kgf・m, 6.6 lb・ft) 2

1 4
3
FW 35 N・m (3.5 kgf・m, 26 lb・ft)
D

The following procedure applies to both of
the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Brake pad 2
The tightening torque of the front brake hose
5 Front brake hose holder bolt 1 holder bolt on the right side is 7 N·m (0.7
kgf·m, 5.2 lb·ft).
7 Front reflector 1
9 Bleed screw 1 Left brake caliper side
10 Bleed screw 1 Right brake caliper side
4-40
FRONT BRAKE
Removing the front brake master cylinder
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)

1.0 N・m (0.10 kgf・m, 0.73 lb・ft) 1
9
2
S
10
7
5 8
S
11
7
4
6
6 N・m (0.6 kgf・m, 4.4 lb・ft)
1.2 N・m (0.12 kgf・m, 0.88 lb・ft) 12

FW
30 N・m (3.0 kgf・m, 22 lb・ft) D

panel/Meter assembly 4-1.
Handlebar cover Refer to “HANDLEBAR” on page 4-79.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-17.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm
2 1
holder
3 Brake master cylinder reservoir diaphragm 1
4 Front brake lever 1
5 Front brake light switch connector 2 Disconnect. For XP530E-A/XP530-A
6 Brake hose union bolt 1
7 Brake hose gasket 2
8 Front brake hose 1
9 Front brake master cylinder holder 1
10 Front brake master cylinder 1
11 Front brake light switch 1 For XP530E-A/XP530-A
12 Front brake light switch 1 For XP530D-A
4-41
FRONT BRAKE
Disassembling the front brake master cylinder

1 Brake master cylinder kit 1
2 Brake master cylinder body 1
4-42
FRONT BRAKE
Removing the front brake calipers
9 N・m (0.9 kgf・m, 6.6 lb・ft)
2
1 3
8
6
7
30 N・m (3.0 kgf・m, 22 lb・ft) 5
FW 4
D
35 N・m (3.5 kgf・m, 26 lb・ft)

Drain.
The tightening torque of the front brake hose
1 Front brake hose holder bolt 1 holder bolt on the right side is 7 N·m (0.7
kgf·m, 5.2 lb·ft).
3 Front reflector 1
5 Brake hose gasket 1 Left side only
6 Front brake hose 1 Left side only
8 Brake hose 1
4-43
FRONT BRAKE
Disassembling the front brake calipers
FW
D 5 N・m (0.5 kgf・m, 3.7 lb・ft)
8 9
5 N・m (0.5 kgf・m, 3.7 lb・ft)
3
2
6
BF
7
5
6
1
BF
BF
6
7
5
BF
6

1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Front brake pad 2
5 Brake caliper piston 4
6 Brake caliper piston dust seal 4
7 Brake caliper piston seal 4
8 Bleed screw 1 Left brake caliper side
9 Bleed screw 1 Right brake caliper side
4-44
FRONT BRAKE
EAS30168
d. Hold the dial gauge at a right angle against
INTRODUCTION the brake disc surface.
EWA14101
WARNING e. Measure the runout 1.5 mm (0.06 in) below

the edge of the brake disc.
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
• Never disassemble brake components un-
less absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly.
• Never use solvents on internal brake com-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ponents.
• Use only clean or new brake fluid for clean- 4. Measure:
ing brake components. • Brake disc thickness
• Brake fluid may damage painted surfaces Measure the brake disc thickness at a few dif-
and plastic parts. Therefore, always clean ferent locations.
up any spilt brake fluid immediately. Out of specification  Replace.
• Avoid brake fluid coming into contact with
Brake disc thickness limit
the eyes as it can cause serious injury.
3.5 mm (0.14 in)
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.
EAS30169
CHECKING THE FRONT BRAKE DISCS

The following procedure applies to both brake
discs.
1. Remove:
• Front wheel
Refer to “FRONT WHEEL” on page 4-22.
2. Check: 5. Adjust:
• Front brake disc • Brake disc runout
Damage/galling  Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3. Measure: a. Remove the brake disc.
• Brake disc runout b. Rotate the brake disc by one bolt hole.
Out of specification  Correct the brake disc c. Install the brake disc.
runout or replace the brake disc. Front brake disc bolt
Brake disc runout limit (as mea- 23 N·m (2.3 kgf·m, 17 lb·ft)
T.
LOCTITE®
R.
sured on wheel)
0.15 mm (0.0059 in)
ECA19150
NOTICE
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the vehicle on a maintenance stand so Replace the brake disc bolts with new ones.
that the front wheel is elevated. TIP
b. Before measuring the brake disc runout, turn Tighten the brake disc bolts in stages and in a
the handlebar to the left or right to ensure that crisscross pattern.
the front wheel is stationary.
c. Remove the brake caliper.
4-45
FRONT BRAKE
d. Measure the brake disc runout.

3. Measure:
e. If out of specification, repeat the adjustment
• Brake pad wear limit “a”
steps until the brake disc runout is within
Out of specification  Replace the brake
specification.
pads as a set.
f. If the brake disc runout cannot be brought
within specification, replace the brake disc. Brake pad lining thickness
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4.0 mm (0.16 in)
Limit
6. Install:
0.5 mm (0.02 in)
• Front wheel
Refer to “FRONT WHEEL” on page 4-22.
EAS30170
REPLACING THE FRONT BRAKE PADS

The following procedure applies to both brake
calipers.
TIP
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem-
ble the brake caliper.
1. Remove:
• Brake pad clips “1” 4. Remove:
• Brake pad pin “2” • Brake caliper bolts
• Brake pad spring 5. Install:
• Brake pads
• Brake pad spring
TIP
Always install new brake pads and new brake
pad spring as a set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2 a. Connect a clear plastic hose “1” tightly to the

1 bleed screw “2”. Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
2. Remove: caliper pistons into the brake caliper with your
• Brake pads “1” finger.
4-46
FRONT BRAKE
1 a
2
LOWER
c. Tighten the bleed screw. 8. Check:

• Brake lever operation
Brake caliper bleed screw Soft or spongy feeling  Bleed the brake sys-
5 N·m (0.5 kgf·m, 3.7 lb·ft)
tem.
T.
R.
d. Install the brake pads and brake pad spring. Refer to “BLEEDING THE HYDRAULIC
TIP
The arrow mark “a” on the brake pad spring EAS30724
must point in the direction of disc rotation. REMOVING THE FRONT BRAKE CALIPERS
brake calipers.
TIP
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
• Brake hose union bolts “1”
• Brake hose gaskets “2”
• Brake hoses “3”
TIP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Put the end of the brake hose into a container
and pump out the brake fluid carefully.
6. Install:
• Brake pad pin
• Brake pad clips
• Front brake caliper 3
1
Front brake caliper bolt
35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
7. Check:
• Brake fluid level
Below the minimum level mark “a”  Add the 2
specified brake fluid to the proper level.
3
1
2
4-47
FRONT BRAKE
EAS30172
DISASSEMBLING THE FRONT BRAKE Recommended brake component

CALIPERS replacement schedule
The following procedure applies to both of the Brake pads If necessary
brake calipers.
1. Remove: Piston seals Every two years
• Brake caliper pistons “1” Piston dust seals Every two years
• Brake caliper piston dust seals “2”
Brake hoses Every four years
• Brake caliper piston seals “3”
Every two years and
1 1 Brake fluid whenever the brake is
disassembled
1. Check:
• Brake caliper pistons “1”
Rust/scratches/wear  Replace the brake
2 caliper pistons.
2
• Brake caliper cylinders “2”
Scratches/wear  Replace the brake caliper
3 3 assembly.
• Brake caliper body “3”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Cracks/damage  Replace the brake caliper
a. Secure the right side brake caliper pistons assembly.
with a piece of wood “a”.
• Brake fluid delivery passages
b. Blow compressed air into the brake hose joint (brake caliper body)
opening “b” to force out the left side pistons Obstruction  Blow out with compressed air.
from the brake caliper. EWA13611
EWA17060
WARNING
WARNING
Whenever a brake caliper is disassembled,
• Never try to pry out the brake caliper pis- replace the brake caliper piston dust seals
tons. and brake caliper piston seals.
• Do not loosen the bolts “4”.
4
2 2
1 1
a b
EAS30174
c. Remove the brake caliper piston dust seals ASSEMBLING THE FRONT BRAKE
and brake caliper piston seals. CALIPERS
EWA16560
d. Repeat the previous steps to force out the
WARNING
right side pistons from the brake caliper.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
EAS30173 with clean or new brake fluid.
CHECKING THE FRONT BRAKE CALIPERS • Never use solvents on internal brake com-
The following procedure applies to both of the ponents as they will cause the brake caliper
brake calipers. piston dust seals and brake caliper piston
seals to swell and distort.
• Whenever a brake caliper is disassembled,
4-48
FRONT BRAKE
replace the brake caliper piston dust seals 2. Remove:

and brake caliper piston seals. • Front brake caliper
3. Install:
Specified brake fluid • Brake pads
DOT 4 • Brake pad spring
• Brake pad pin
EAS30175
• Brake pad clips
INSTALLING THE FRONT BRAKE CALIPERS • Front brake caliper
brake calipers. Front brake caliper bolt
1. Install: 35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
• Front brake caliper “1”
(temporarily) Refer to “REPLACING THE FRONT BRAKE
• Brake hose gaskets New PADS” on page 4-46.
• Brake hose “2” 4. Fill:
• Brake hose union bolt “3” • Brake master cylinder reservoir
(with the specified amount of the specified
Front brake hose union bolt brake fluid)
30 N·m (3.0 kgf·m, 22 lb·ft)
T.

R.
EWA13531
DOT 4
WARNING
Proper brake hose routing is essential to in- EWA13090
WARNING
sure safe vehicle operation.
ECA21410
NOTICE brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
• When installing the brake hose onto the
brake performance.
brake caliper “1”, make sure the brake pipe
• Refill with the same type of brake fluid that
“a” touches the projection “b” on the brake
is already in the system. Mixing brake fluids
caliper.
may result in a harmful chemical reaction,
• Install the brake pipe “c” so that it is
leading to poor brake performance.
aligned with the brake pipe “a”.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
b
2 will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
3
ECA13540
NOTICE
a
1 any spilt brake fluid immediately.
5. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
2 BRAKE SYSTEM” on page 3-17.
c 6. Check:
a • Brake fluid level
b Below the minimum level mark “a”  Add the
3 specified brake fluid to the proper level.
1 LEVEL” on page 3-15.
4-49
FRONT BRAKE
(brake master cylinder body)

a Obstruction  Blow out with compressed air.
2. Check:
LOWER • Brake master cylinder kit
Damage/scratches/wear  Replace.
3. Check:
• Brake master cylinder reservoir cap “1”
• Brake master cylinder reservoir “2”
• Brake master cylinder reservoir diaphragm
holder “3”
7. Check:
“4”
Soft or spongy feeling  Bleed the brake sys-
tem.
1
EAS30179
3
REMOVING THE FRONT BRAKE MASTER
4
CYLINDER
TIP
Before removing the front brake master cylinder, 2
drain the brake fluid from the entire brake sys-
tem.
1. Disconnect: 4. Check:
• Brake light switch connectors • Brake hoses
(from the front brake light switch) Cracks/damage/wear  Replace.
2. Remove:
• Brake hose union bolt “1” EAS30181
ASSEMBLING THE FRONT BRAKE MASTER

• Brake hose gaskets “2”
CYLINDER
• Brake hose “3” EWA13520
TIP WARNING
To collect any remaining brake fluid, place a • Before installation, all internal brake com-
container under the master cylinder and the end ponents should be cleaned and lubricated
of the brake hose. with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents.
2
1 Specified brake fluid
3 DOT 4
EAS30182
INSTALLING THE FRONT BRAKE MASTER

CYLINDER
1. Install:
• Front brake master cylinder “1”
EAS30725 • Front brake master cylinder holder “2”
CHECKING THE FRONT BRAKE MASTER
CYLINDER Front brake master cylinder hold-
1. Check: er bolt
T.
10 N·m (1.0 kgf·m, 7.4 lb·ft)

R.
• Brake master cylinder

• Brake fluid delivery passages
4-50
FRONT BRAKE
TIP sure the brake hose does not touch other parts
• Install the front brake master cylinder holder (e.g., wire harness, cables, leads). Correct if
with the “ ” mark “a” facing up. necessary.
• Make sure that brake master cylinder assem-
bly touches the end of handlebar bracket “b”.
• Install the brake master cylinder assembly to
the handlebar “3” at the specified angle “c”. 1
3
• First, tighten the upper bolt, then the lower bolt. 2
Angle “c” (brake master cylinder

and handlebar bracket)
120.1–122.7
a
3. Fill:
b • Brake master cylinder reservoir
2 (with the specified amount of the specified
brake fluid)
a DOT 4
1
EWA13540
WARNING
brake fluids may cause the rubber seals to
3 brake performance.
1 • Refill with the same type of brake fluid that
b may result in a harmful chemical reaction,
c leading to poor brake performance.
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
2. Install: ing point of the brake fluid and could cause
• Brake hose gaskets “1” New vapor lock.
• Brake hose “2” ECA13540
• Brake hose union bolt “3” NOTICE
Front brake hose union bolt Brake fluid may damage painted surfaces
30 N·m (3.0 kgf·m, 22 lb·ft) and plastic parts. Therefore, always clean up
T.
R.
any spilt brake fluid immediately.

EWA13531
WARNING 4. Bleed:
Proper brake hose routing is essential to in- • Brake system
sure safe vehicle operation. Refer to “BLEEDING THE HYDRAULIC
ECA14160
NOTICE 5. Check:
When installing the brake hose onto the
Below the minimum level mark “a”  Add the
brake master cylinder, make sure the brake
pipe touches the projection “a” as shown.
TIP LEVEL” on page 3-15.
Turn the handlebar to the left and right to make
4-51
FRONT BRAKE
LOWER
6. Check:
tem.
4-52
REAR BRAKE
EAS20031
REAR BRAKE
Removing the rear brake pads
6 N・m (0.6 kgf・m, 4.4 lb・ft)
3
3
4
5 2
1
1
FW
D
27 N・m (2.7 kgf・m, 20 lb・ft)

1 Rear brake caliper bolt 2
2 Rear brake caliper 1
3 Rear brake pad 2
4 Brake pad support 2
5 Bleed screw 1
4-53
REAR BRAKE
Removing the rear brake master cylinder
10 N・m (1.0 kgf・m, 7.4 lb・ft)
1.5 N・m (0.15 kgf・m, 1.1 lb・ft) 9
1.0 N・m (0.10 kgf・m, 0.73 lb・ft)

1
S
2
10
7
5
8 S
11
7 4
6
6 N・m (0.6 kgf・m, 4.4 lb・ft)
12 1.2 N・m (0.12 kgf・m, 0.88 lb・ft)
30 N・m (3.0 kgf・m, 22 lb・ft)

Drain.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm
2 1
holder
3 Brake master cylinder reservoir diaphragm 1
4 Rear brake lever 1
5 Rear brake light switch connector 2 Disconnect. For XP530E-A/XP530-A
8 Rear brake hose 1
9 Rear brake master cylinder holder 1
10 Rear brake master cylinder 1
11 Rear brake light switch 1 For XP530E-A/XP530-A
12 Rear brake light switch 1 For XP530D-A
4-54
REAR BRAKE
Disassembling the rear brake master cylinder
S
BF

1 Brake master cylinder kit 1
2 Brake master cylinder body 1
4-55
REAR BRAKE
Removing the rear brake caliper
6
6
30 N・m (3.0 kgf・m, 22 lb・ft)
7
2
8
5 S
3 S
1
4
4
S FW
D
27 N・m (2.7 kgf・m, 20 lb・ft)

Drain.
3 Rear brake hose 1
4 Rear brake caliper bolt 2
5 Rear brake caliper 1
6 Rear brake pad 2
7 Brake pad support 2
8 Caliper bolt boot 2
4-56
REAR BRAKE
Disassembling the rear brake caliper
6 N・m (0.6 kgf・m, 4.4 lb・ft)
3
4
BF
FW
D

1 Brake caliper piston 1
2 Brake caliper piston dust seal 1
3 Brake caliper piston seal 1
4 Bleed screw 1
5 Brake caliper body 1
4-57
REAR BRAKE
Removing the rear brake lock pads
23 N・m (2.3 kgf・m, 17 lb・ft)
5
4
FW
D

1 Rear brake lock cable adjusting nut 1
2 Pin 1
3 Rear brake lock spring 1
4 Rear brake lock caliper 1
5 Rear brake lock pad 2
4-58
REAR BRAKE
Removing the rear brake lock caliper
23 N・m (2.3 kgf・m, 17 lb・ft)
FW
D

1 Rear brake lock cable adjusting nut 1
2 Pin 1
3 Rear brake lock spring 1
4-59
REAR BRAKE
Disassembling the rear brake lock caliper
10
22 N・m (2.2 kgf・m, 16 lb・ft) 13
S
LT
9
10 6
7
4
3 11
2 S S
12
8
22 N・m (2.2 kgf・m, 16 lb・ft)
FW
15 N・m (1.5 kgf・m, 11 lb・ft) 17 N・m (1.7 kgf・m, 13 lb・ft) D

1 Cap 1
2 Rear brake lock adjusting nut 1
3 Rear brake lock caliper arm 1
4 Boot 1
5 Rear brake lock pad 2
6 Caliper piston assembly 1
7 Rear brake lock caliper bracket bolt 1
8 Rear brake lock caliper bracket 1
9 Sleeve 1
10 Boot 2
11 Boot 1
12 Slide pin bolt 1
4-60
REAR BRAKE
EAS30183
INTRODUCTION Brake disc thickness limit

EWA14101
4.5 mm (0.18 in)
WARNING
Disc brake components rarely require disas- 5. Adjust:
sembly. Therefore, always follow these pre- • Brake disc deflection
ventive measures: Refer to “CHECKING THE FRONT BRAKE
• Never disassemble brake components un- DISCS” on page 4-45.
less absolutely necessary.
Rear brake disc bolt
• If any connection on the hydraulic brake
30 N·m (3.0 kgf·m, 22 lb·ft)
system is disconnected, the entire brake
T.
LOCTITE®
R.
system must be disassembled, drained,
cleaned, properly filled, and bled after reas- 6. Install:
sembly. • Rear wheel
• Never use solvents on internal brake com- Refer to “REAR WHEEL” on page 4-31.
ponents.
• Use only clean or new brake fluid for clean- EAS30185
ing brake components. REPLACING THE REAR BRAKE PADS

• Brake fluid may damage painted surfaces TIP
and plastic parts. Therefore, always clean When replacing the brake pads, it is not neces-
up any spilt brake fluid immediately. sary to disconnect the brake hose or disassem-
• Avoid brake fluid coming into contact with ble the brake caliper.
the eyes as it can cause serious injury. 1. Remove:
FIRST AID FOR BRAKE FLUID ENTERING • Rear brake caliper bolts “1”
THE EYES: • Rear brake caliper “2”
• Flush with water for 15 minutes and get im-
mediate medical attention. 1
EAS30184
CHECKING THE REAR BRAKE DISC

1. Remove:
• Rear wheel
Refer to “REAR WHEEL” on page 4-31. 2
2. Check:
• Rear brake disc 1
Damage/galling  Replace.
3. Measure: 2. Remove:
• Brake disc runout • Rear brake pads “1”
Out of specification  Correct the brake disc • Brake pad supports “2”
deflection or replace the brake disc.
Refer to “CHECKING THE FRONT BRAKE 2
DISCS” on page 4-45.
Brake disc runout limit (as mea-
sured on wheel)
0.15 mm (0.0059 in) 1
4. Measure:
• Brake disc thickness 2
Measure the brake disc thickness at a few dif-
ferent locations. 3. Measure:
Out of specification  Replace. • Brake pad wear limit “a”
Refer to “CHECKING THE FRONT BRAKE Out of specification  Replace the brake
DISCS” on page 4-45. pads as a set.
4-61
REAR BRAKE
ECA14150
Brake pad lining thickness NOTICE

8.0 mm (0.31 in) • Do not allow grease to contact the brake
Limit pads.
0.8 mm (0.03 in)
• Remove any excess grease.
6. Install:
• Rear brake caliper
• Rear brake caliper bolts
Rear brake caliper bolt
27 N·m (2.7 kgf·m, 20 lb·ft)
T.
R.
7. Check:
Below the minimum level mark “a” Add the
4. Install: Refer to “CHECKING THE BRAKE FLUID
• Brake pad supports LEVEL” on page 3-15.
• Rear brake pads
TIP a
Always install new brake pads, brake pad sup-
ports as a set. LOWER
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose “1” tightly to the
bleed screw “2”. Put the other end of the hose
into an open container.
8. Check:
tem.
EAS30186
REMOVING THE REAR BRAKE CALIPER

b. Loosen the bleed screw and push the brake
caliper piston into the brake caliper with your TIP
Before removing the brake caliper, drain the
finger.
brake fluid from the entire brake system.
c. Tighten the bleed screw.
1. Remove:
Rear brake caliper bleed screw • Brake hose union bolt “1”
6 N·m (0.6 kgf·m, 4.4 lb·ft)
• Brake hose gaskets
T.
R.
d. Install brake pad supports and brake pads. • Rear brake hose “2”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP
Put the end of the brake hose into a container
5. Lubricate: and pump out the brake fluid carefully.
• Rear brake caliper bolts
Silicone grease
4-62
REAR BRAKE
EAS30188
CHECKING THE REAR BRAKE CALIPER

Recommended brake component replacement
schedule
Brake pads If necessary

Piston seal Every two years
2
Piston dust seal Every two years
1 Brake hoses Every four years
Every two years and
EAS30187
Brake fluid whenever the brake is
DISASSEMBLING THE REAR BRAKE disassembled
CALIPER
1. Remove: 1. Check:
• Brake caliper piston “1” • Brake caliper piston “1”
• Brake caliper piston dust seal “2” Rust/scratches/wear  Replace the brake
• Brake caliper piston seal “3” caliper piston.
• Brake caliper cylinder “2”
Scratches/wear  Replace the brake caliper
assembly.
• Brake caliper body “3”
Cracks/damage  Replace the brake caliper
assembly.
1
2 • Brake fluid delivery passages
3 (brake caliper body)
Obstruction  Blow out with compressed air.
EWA13601
WARNING
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Whenever a brake caliper is disassembled,
a. Blow compressed air into the brake hose joint replace the brake caliper piston dust seal
opening “a” to force out the piston from the and brake caliper piston seal.
brake caliper.
EWA13550
WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
2. Check:
• Brake caliper bracket “1”
Refer to “REAR WHEEL” on page 4-31.
b. Remove the brake caliper piston dust seal

and brake caliper piston seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-63
REAR BRAKE
2
a
b
3
1
EAS30189
ASSEMBLING THE REAR BRAKE CALIPER 2. Remove:

EWA17080 • Rear brake caliper
WARNING 3. Install:
• Before installation, all internal brake com- • Brake pad supports
ponents should be cleaned and lubricated • Rear brake pads
with clean or new brake fluid. • Rear brake caliper
• Never use solvents on internal brake com- • Rear brake caliper bolt
ponents as they will cause the brake caliper Refer to “REPLACING THE REAR BRAKE
piston dust seal and brake caliper piston PADS” on page 4-61.
seal to swell and distort. Rear brake caliper bolt
• Whenever a brake caliper is disassembled, 27 N·m (2.7 kgf·m, 20 lb·ft)
replace the brake caliper piston dust seal
T.
R.
and brake caliper piston seal. 4. Fill:

• Brake master cylinder reservoir
Specified brake fluid (with the specified amount of the specified
DOT 4 brake fluid)
EAS30190 Specified brake fluid
INSTALLING THE REAR BRAKE CALIPER DOT 4
1. Install:
• Rear brake caliper “1” EWA13540
WARNING
(temporarily)
• Brake hose gaskets New • Use only the designated brake fluid. Other
• Rear brake hose “2” brake fluids may cause the rubber seals to
• Brake hose union bolt “3” deteriorate, causing leakage and poor
brake performance.
Rear brake hose union bolt • Refill with the same type of brake fluid that
30 N·m (3.0 kgf·m, 22 lb·ft) is already in the system. Mixing brake fluids
T.
R.
EWA13531
WARNING leading to poor brake performance.
Proper brake hose routing is essential to in-
not enter the brake master cylinder reser-
sure safe vehicle operation.
voir. Water will significantly lower the boil-
ECA14170
ing point of the brake fluid and could cause
NOTICE
vapor lock.
When installing the brake hose onto the ECA13540
brake caliper “1”, make sure the brake pipe NOTICE
“a” touches the projection “b” on the brake
caliper.
any spilt brake fluid immediately.
5. Bleed:
• Brake system
4-64
REAR BRAKE
Refer to “BLEEDING THE HYDRAULIC EAS30194
BRAKE SYSTEM” on page 3-17. CHECKING THE REAR BRAKE MASTER

6. Check: CYLINDER
• Brake fluid level 1. Check:
Below the minimum level mark “a” Add the • Brake master cylinder
specified brake fluid to the proper level. Damage/scratches/wear  Replace.
Refer to “CHECKING THE BRAKE FLUID • Brake fluid delivery passages
LEVEL” on page 3-15. (brake master cylinder body)
a 2. Check:
• Brake master cylinder kit
LOWER
3. Check:
• Brake master cylinder reservoir cap
holder
4. Check:
7. Check: • Brake hose
• Brake lever operation Cracks/damage/wear  Replace.
EAS30195
tem. ASSEMBLING THE REAR BRAKE MASTER
Refer to “BLEEDING THE HYDRAULIC CYLINDER
BRAKE SYSTEM” on page 3-17. EWA13520
EAS30193
WARNING
REMOVING THE REAR BRAKE MASTER • Before installation, all internal brake com-
CYLINDER ponents should be cleaned and lubricated
TIP with clean or new brake fluid.
Before removing the rear brake master cylinder, • Never use solvents on internal brake com-
drain the brake fluid from the entire brake sys- ponents.
tem.
1. Remove: DOT 4
• Brake hose union bolt “1”
• Brake hose gaskets “2” 1. Install:
• Rear brake hose “3” • Brake master cylinder kit New
TIP
To collect any remaining brake fluid, place a EAS30196
INSTALLING THE REAR BRAKE MASTER

container under the master cylinder and the end
CYLINDER
of the brake hose.
1. Install:
• Brake master cylinder “1”
• Rear brake master cylinder holder “2”
2
Brake master cylinder holder bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
3 TIP
• Make sure that the brake master cylinder as-
sembly touches the end of handlebar bracket
1 “a”.
• Install the brake master cylinder assembly to
the handlebar “3” at the specified angle “b”.
4-65
REAR BRAKE
• First, tighten the upper bolt, then the lower bolt.

1
Angle “b” (brake master cylinder
and handlebar bracket) a
120.1–122.7
2
a
a 3
3. Fill:
1 (with the specified amount of the specified
brake fluid)
2
DOT 4
EWA13540
b WARNING
brake fluids may cause the rubber seals to
a brake performance.
1 3 • Refill with the same type of brake fluid that
2. Install: leading to poor brake performance.
• Brake hose gaskets “1” New • When refilling, be careful that water does
• Rear brake hose “2” not enter the brake master cylinder reser-
• Brake hose union bolt “3” voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
Rear brake hose union bolt vapor lock.
30 N·m (3.0 kgf·m, 22 lb·ft)
T.
ECA13540
R.
EWA13531 NOTICE
WARNING Brake fluid may damage painted surfaces
Proper brake hose routing is essential to in- and plastic parts. Therefore, always clean up
sure safe vehicle operation. any spilt brake fluid immediately.
ECA14160 4. Bleed:
NOTICE • Brake system
When installing the brake hose onto the Refer to “BLEEDING THE HYDRAULIC
brake master cylinder, make sure the brake BRAKE SYSTEM” on page 3-17.
pipe touches the projection “a” as shown. 5. Check:
TIP
Turn the handlebar to the left and right to make Below the minimum level mark “a” Add the
sure that the brake hose does not touch other specified brake fluid to the proper level.
parts (e.g., wire harness, cables, leads). Correct Refer to “CHECKING THE BRAKE FLUID
if necessary. LEVEL” on page 3-15.
4-66
REAR BRAKE
LOWER
1
6. Check: TIP
• Brake lever operation Push on the back of the pad using a rod with a
Soft or spongy feeling  Bleed the brake sys- round end.
tem.
4. Remove:
• Rear brake lock pad (right side) “1”
EAS31417
REPLACING THE REAR BRAKE LOCK PADS

1. Remove:
• Rear brake lock cable adjusting nut “1”
• Pin “2”
• Rear brake lock spring “3”
1
3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bolt “2”, and then slide the rear
brake lock caliper bracket “3”.
1
2
2
2. Remove:
• Rear brake lock caliper bolts “1”
• Rear brake lock caliper “2”
3
2 1
b. Insert a flathead screwdriver in between the

piston adjusting bolt and rear brake lock pad
and then remove the rear brake lock pad.
ECA22110
1 NOTICE
Avoid scratching the dust seal on the side of
the piston adjusting bolt carefully.
3. Remove:
• Rear brake lock pad (left side) “1”
4-67
REAR BRAKE
Rear brake lock caliper bolt

23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
10.Adjust:
EAS31418
REPLACING THE REAR BRAKE LOCK

CABLE
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1. Remove:
5. Measure: • Rear brake lock cable
• Rear brake lock pads wear limit “a” 2. Check:
Out of specification  Replace the rear brake • Rear brake lock cable
lock pads. Cracks/damage/wear  Replace the rear
brake lock cable.
Brake pad lining thickness 3. Install:
3.0 mm (0.12 in) • Rear brake lock cable
Limit EWA13490
0.8 mm (0.03 in) WARNING

Make sure the brake cable is routed properly.
4. Adjust:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Adjust the clearance for the rear brake lock
pad.
b. Activate the rear brake lock cable 10 times.
c. Carry out adjustment using rear brake lock
6. Remove: cable adjusting nut “1” so that dimension “a”
• Cap is 43–45 mm (1.69–1.77 in).
• Rear brake lock adjusting nut d. Repeat steps (a) to (c) until dimension “a” is
• Rear brake lock caliper arm 43–45 mm (1.69–1.77 in).
7. Adjust:
• Piston adjusting bolt
Refer to “ASSEMBLING THE REAR BRAKE
LOCK CALIPER” on page 4-69.
8. Install:
• Rear brake lock caliper arm
• Rear brake lock adjusting nut
• Cap
• Rear brake lock pads
Refer to “ASSEMBLING THE REAR BRAKE
LOCK CALIPER” on page 4-69. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9. Install:
• Rear brake lock caliper EAS31419
• Rear brake lock caliper bolts REMOVING THE REAR BRAKE LOCK
• Rear brake lock spring CALIPER
• Pin 1. Remove:
• Rear brake lock cable adjusting nut • Rear brake lock cable adjusting nut “1”
• Pin “2”
4-68
REAR BRAKE

3
5
4
1 2 4 2. Install:
• Rear brake lock caliper bracket
Rear brake lock caliper bracket
EAS31420 bolt
CHECKING THE REAR BRAKE LOCK
T.
22 N·m (2.2 kgf·m, 16 lb·ft)
R.
CALIPER LOCTITE®
1. Check:
• Rear brake lock caliper arm “1” 3. Install:
• Rear brake lock caliper bracket “2” • Boots “1”
• Sleeve “3” • Sleeve “2”
• Locknut “5” Recommended lubricant
Silicone grease
• Shaft L “6”
• Piston adjusting bolt “7”
• Boots “8”
8
3
8
7
1
2
4
5 8 4. Install:
6
8 • Boot “1”
EAS31421
ASSEMBLING THE REAR BRAKE LOCK

CALIPER
1. Install:
• Slide pin bolt “1”
(to the rear brake lock caliper bracket)
Rear brake lock caliper slide pin
bolt
T.
17 N·m (1.7 kgf·m, 13 lb·ft)

R.
5. Install:
• Shaft L “1”
Recommended lubricant • Piston adjusting bolt “2”
Silicone grease • Locknut “3”
Silicone grease
4-69
REAR BRAKE
Rear brake lock caliper piston

locknut
T.
22 N·m (2.2 kgf·m, 16 lb·ft)

R.
Left-hand thread
8. Install:
• Rear brake lock adjusting nut
• Cap
Rear brake lock adjusting nut
15 N·m (1.5 kgf·m, 11 lb·ft)
6. Adjust:
T.
R.
• Piston adjusting bolt 9. Install:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Rear brake lock pads
a. Tighten shaft L manually until it touches the ECA22120
locknut. NOTICE
b. With shaft L fastened, turn and adjust the pis- After installing the rear brake lock pad to the
ton adjusting bolt so that the length “a” be- caliper, check that the pad rotates smoothly.
tween the end of shaft L and the end of the
piston adjusting bolt is changed to 19 mm EAS31422
(0.75 in). INSTALLING THE REAR BRAKE LOCK

CALIPER
1. Install:
• Pin “4”
• Rear brake lock cable adjusting nut “5”
Rear brake lock caliper bolt
23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Install: 3
1 2
• Boot
• Rear brake lock caliper arm
TIP
• Check that the boot is installed correctly.
• Install rear brake lock caliper arm “1” in the po-
5
sition closest to cable holder “2”. 4 2
2. Adjust:
4-70
ABS (Anti-lock Brake System)
EAS20032

Removing the hydraulic unit assembly
30 N・m (3.0 kgf・m, 22 lb・ft)
2 7 N・m (0.7 kgf・m, 5.2 lb・ft)
2
3 3
4
7
6
5
9
3
3
1
8
7 N・m (0.7 kgf・m, 5.2 lb・ft)

panel/Front cowling assembly
Drain.
1 ABS ECU coupler 1 Disconnect.
Rear brake hose (rear brake master cylinder to
4 1 Disconnect.
hydraulic unit)
Front brake hose (hydraulic unit to front brake
5 1 Disconnect.
caliper)
Front brake hose (front brake master cylinder to
6 1 Disconnect.
hydraulic unit)
Rear brake hose (hydraulic unit to rear brake
7 1 Disconnect.
caliper)
8 Hydraulic unit assembly 1
9 Hydraulic unit assembly bracket 1
4-71
EAS30728
ABS COMPONENTS CHART
11
2 14
12
13
4
3
1
10
9
8 7 6
1. Yamaha diagnostic tool coupler
2. ABS warning light
3. ABS ECU fuse/ABS solenoid fuse/ABS motor
fuse
4. Hydraulic unit assembly
5. Front wheel sensor rotor
7. Front brake caliper
10.Rear wheel sensor rotor
11.Front brake hose (front brake master cylinder
to hydraulic unit)
12.Front brake hose (hydraulic unit to front brake
caliper)
13.Rear brake hose (hydraulic unit to rear brake
caliper)
to hydraulic unit)
4-72
EAS30197
REMOVING THE HYDRAULIC UNIT

ASSEMBLY 1
ECA18230
NOTICE
Unless necessary, avoid removing and in-
stalling the brake pipes of the hydraulic unit
assembly.
EWA13930
WARNING a
Refill with the same type of brake fluid that is
already in the system. Mixing fluids may re- 2. Remove:
sult in a harmful chemical reaction, leading • Brake hoses
to poor braking performance. TIP
ECA22100
Do not operate the front brake lever and rear
NOTICE brake lever while removing the brake hoses.
• Handle the ABS components with care ECA18251
since they have been accurately adjusted. NOTICE

Keep them away from dirt and do not sub- When removing the brake hoses, cover the
ject them to shocks. area around the hydraulic unit assembly to
• Do not push the ON/start switch when re- catch any spilt brake fluid. Do not allow the
moving the hydraulic unit assembly. brake fluid to contact other parts.
• Do not clean with compressed air. 3. Remove:
• Do not reuse the brake fluid. • Hydraulic unit assembly “1”
• Brake fluid may damage painted surfaces TIP
and plastic parts. Therefore, always clean • To avoid brake fluid leakage and to prevent for-
up any spilt brake fluid immediately. eign materials from entering the hydraulic unit
• Do not allow any brake fluid to contact the assembly, insert a rubber plug “a” or a bolt
couplers. Brake fluid may damage the cou- (M10  1.00) into each brake hose union bolt
plers and cause bad contacts. hole.
• If the union bolts for the hydraulic unit as- • When using a bolt, do not tighten the bolt until
sembly have been removed, be sure to the bolt head touches the hydraulic unit. Other-
tighten them to the specified torque and wise, the brake hose union bolt seating surface
bleed the brake system. could be deformed.
1. Disconnect:
• ABS ECU coupler “1”
TIP
While pushing the portion “a” of the ABS ECU a
coupler, pull the lock lever up to release the lock.
ECA20080
NOTICE
1
Do not use a tool to disconnect the ABS ECU
coupler.
EAS30198
CHECKING THE HYDRAULIC UNIT

ASSEMBLY
1. Check:
• Hydraulic unit assembly
Cracks/damage  Replace the hydraulic unit
assembly and the brake hoses that are con-
nected to the assembly as a set.
4-73
EAS30200
TIP
INSTALLING THE HYDRAULIC UNIT Connect the ABS ECU coupler, and then push
ASSEMBLY the lock lever of the coupler in the direction of the
1. Install: arrow shown.
• Hydraulic unit assembly
ECA21371
NOTICE
Do not remove the rubber plugs or bolts 1
(M10  1.0) installed in the brake hose union
bolt holes before installing the hydraulic unit
assembly.
TIP
Do not allow any foreign materials to enter the
hydraulic unit assembly or the brake hoses
when installing the hydraulic unit assembly.
2. Remove: 5. Fill:
• Rubber plugs or bolts (M10  1.0) • Brake master cylinder reservoir
3. Install: • Brake fluid reservoir
• Rear brake hose (hydraulic unit to rear brake (with the specified amount of the specified
caliper) “1” brake fluid)
• Front brake hose (front brake master cylinder Specified brake fluid
to hydraulic unit) “2” DOT 4
• Front brake hose (hydraulic unit to front brake
caliper) “3” EWA13090
• Rear brake hose (rear brake master cylinder WARNING

to hydraulic unit) “4” • Use only the designated brake fluid. Other
• Gasket New brake fluids may cause the rubber seals to
• Brake hose union bolts deteriorate, causing leakage and poor
brake performance.
Brake hose union bolt • Refill with the same type of brake fluid that
30 N·m (3.0 kgf·m, 22 lb·ft) is already in the system. Mixing brake fluids
T.
R.
ECA21121
NOTICE leading to poor brake performance.
If the brake hose union bolt does not turn • When refilling, be careful that water does
easily, replace the hydraulic unit assembly, not enter the brake fluid reservoir. Water
brake hoses, and related parts as a set. will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
TIP ECA13540
To route the brake hose, refer to “CABLE NOTICE
ROUTING” on page 2-33.
4 any spilt brake fluid immediately.
1 6. Bleed:
• Brake system
2 BRAKE SYSTEM” on page 3-17.
7. Check the operation of the hydraulic unit ac-
cording to the front brake lever and the rear
3 brake lever response. (Refer to “HYDRAU-
LIC UNIT OPERATION TEST” on page
4. Connect: 4-75.)
• ABS ECU coupler “1”
4-74
ECA14550
TIP
NOTICE If the battery voltage is lower than 12.8 V, charge
Always check the operation of the hydraulic the battery, and then perform brake line routing
unit according to the brake lever response. confirmation.
8. Delete the fault codes. (Refer to “[B-3] DE-
LETING THE FAULT CODES” on page
8-191.)
9. Perform a trial run. (Refer to “CHECKING
THE ABS WARNING LIGHT” on page 4-78.)
EAS30201
HYDRAULIC UNIT OPERATION TEST

The reaction-force pulsating action generated in
the front brake lever and rear brake lever when
the ABS is activated can be tested when the ve-
hicle is stopped.
5. Removing the protective cap “1”, and then
The hydraulic unit operation can be tested using
connect the Yamaha diagnostic tool to the
the following two methods.
Yamaha diagnostic tool coupler (4P).
• Brake line routing confirmation: this test
checks the function of the ABS after the sys- Yamaha diagnostic tool USB
tem was disassembled, adjusted, or serviced. 90890-03256
• ABS reaction-force confirmation: this test gen- Yamaha diagnostic tool (A/I)
erates the same reaction-force pulsating action 90890-03254
that is generated in the front brake lever and
rear brake lever when the ABS is activated.
Brake line routing confirmation
EWA13120
WARNING 1
TIP
• For the brake line routing confirmation, use the
diagnosis of function of the Yamaha diagnostic
tool.
• Before performing the brake line routing confir- 6. Start the Yamaha diagnostic tool and display
mation, make sure that no malfunctions have the diagnosis of function screen.
been detected in the ABS ECU and that the 7. Select code No. 2, “Brake line routing confir-
wheels are not rotating. mation”.
8. Click “Actuator Check” “1”, and then operate
1. Place the vehicle on a maintenance stand. the front brake lever “2” and rear brake lever
2. Push the OFF/LOCK switch. “3” simultaneously.
3. Remove:
TIP
• Battery cover • The hydraulic unit operates 1 second after the
Refer to “GENERAL CHASSIS (1)” on page front brake lever and rear brake lever are oper-
4-1. ated simultaneously and continues for approx-
4. Check: imately 5 seconds.
• Battery voltage • The operation of the hydraulic unit can be con-
Lower than 12.8 V  Charge or replace the firmed using the indicator.
battery. On: The hydraulic unit is operating.
Battery voltage Flashing: The conditions for operating the hy-
Higher than 12.8 V draulic unit have not been met.
Off: The front brake lever and rear brake lever
are not being operated.
4-75
the brake hoses and brake pipes are con-

nected correctly to the hydraulic unit as-
sembly.
10.If the operation of the hydraulic unit is normal,
delete all of the fault codes.
ABS reaction-force confirmation
EWA13120
WARNING
1
TIP
• For the ABS reaction-force confirmation, use
the diagnosis of function of the Yamaha diag-
nostic tool. For more information, refer to the
operation manual of the Yamaha diagnostic
tool.
• Before performing the ABS reaction-force con-
firmation, make sure that no malfunctions have
2 3 been detected in the ABS ECU and that the
wheels are not rotating.
9. Check:
• Hydraulic unit operation 1. Place the vehicle on a maintenance stand.
Click “Actuator Check”, a single pulse will be 2. Push the OFF/LOCK switch.
generated in the front brake lever “1”, rear 3. Remove:
brake lever “2”, and again in the front brake • Battery cover
lever “1”, in this order. Refer to “GENERAL CHASSIS (1)” on page
4-1.
4. Check:
• Battery voltage
Lower than 12.8 V  Charge or replace the
battery.
Battery voltage
Higher than 12.8 V
1 2 TIP
If the battery voltage is lower than 12.8 V, charge
the battery, and then perform ABS reaction-
TIP
force confirmation.
“ON” and “OFF” on the tool screen indicate
when the brakes are being applied and released
respectively.
ECA22080
NOTICE
• Check that the pulse is felt in the front
brake lever, rear brake lever, and again in
the front brake lever, in this order.
• If the pulse is felt in the rear brake lever be-
fore it is felt in the front brake lever, check
that the brake hoses and brake pipes are
connected correctly to the hydraulic unit 5. Removing the protective cap “1”, and then
assembly. connect the Yamaha diagnostic tool to the
• If the pulse is hardly felt in either the front Yamaha diagnostic tool coupler (4P).
brake lever or rear brake lever, check that
4-76
Yamaha diagnostic tool USB

90890-03256
90890-03254
1
2 3
9. A reaction-force pulsating action is generated

in the front brake lever “1” and continues for a
few seconds.
TIP
• The reaction-force pulsating action consists of
6. Start the Yamaha diagnostic tool and display quick pulses.
the diagnosis of function screen. • Be sure to continue operating the front brake
7. Select code No. 1, “ABS reaction-force con- lever and rear brake lever even after the pul-
firmation”. sating action has stopped.
8. Click “Actuator Check” “1”, and then operate • “ON” and “OFF” on the tool screen indicate
the front brake lever “2” and rear brake lever when the brakes are being applied and re-
“3” simultaneously. leased respectively.
TIP
• The hydraulic unit operates 1 second after the
front brake lever and rear brake lever are oper-
ated simultaneously and continues for approx-
imately 5 seconds.
• The operation of the hydraulic unit can be con-
firmed using the indicator.
On: The hydraulic unit is operating.
Flashing: The conditions for operating the hy-
draulic unit have not been met. 1
Off: The front brake lever and rear brake lever
are not being operated. 10.After the pulsating action has stopped in the
front brake lever, it is generated in the rear
brake lever “1” and continues for a few sec-
onds.
TIP
quick pulses.
• Be sure to continue operating the front brake
lever and rear brake lever even after the pul-
sating action has stopped.
• “ON” and “OFF” on the tool screen indicate
1
when the brakes are being applied and re-
leased respectively.
4-77
11.After the pulsating action has stopped in the

rear brake lever, it is generated in the front
brake lever and continues for a few seconds.
TIP
quick pulses.
• “ON” and “OFF” on the tool screen indicate
when the brakes are being applied and re-
leased respectively.
ECA22080
NOTICE
• Check that the pulse is felt in the front
brake lever, rear brake lever, and again in
the front brake lever, in this order.
• If the pulse is felt in the rear brake lever be-
fore it is felt in the front brake lever, check
that the brake hoses and brake pipes are
connected correctly to the hydraulic unit
assembly.
• If the pulse is hardly felt in either the front
brake lever or rear brake lever, check that
the brake hoses and brake pipes are con-
nected correctly to the hydraulic unit as-
sembly.
12.Push the OFF/LOCK switch.
13.Remove the Yamaha diagnostic tool from the
Yamaha diagnostic tool coupler, and then in-
stall the protective cap.
14.Push the ON/start switch.
15.Set the engine stop switch to “ ”.
16.Check for brake fluid leakage around the hy-
draulic unit.
Brake fluid leakage  Replace the hydraulic
unit, brake pipes, and related parts as a set.
17.If the operation of the hydraulic unit is normal,
delete all of the fault codes.
EAS30202
CHECKING THE ABS WARNING LIGHT

After all checks and servicing are completed, en-
sure that the ABS warning light goes off by walk-
ing the vehicle at a speed of faster than 7 km/h
(4.4 mi/h) or performing a trial run.
4-78
HANDLEBAR
EAS20033
HANDLEBAR
Removing the handlebar cover
FW 1
D 1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)

2
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
6 7
5
3 4
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)

2.5 N・m (0.25 kgf・m, 1.8 lb・ft)

1 Upper handlebar cover 1
2 Handlebar cover (front) 1
3 Parking/Unlock switch coupler 1 Disconnect.
4 OFF/LOCK switch coupler 1 Disconnect.
5 Lower handlebar cover 1
6 Accelerator position sensor coupler 1 Disconnect.
7 Handlebar cover (rear) 1
8 Parking/Unlock switch 1
9 OFF/LOCK switch 1
4-79
HANDLEBAR
Removing the handlebar switch and throttle grip
FW
D 26 N・m (2.6 kgf・m, 19 lb・ft)
3.5 N・m (0.35 kgf・m, 2.6 lb・ft)
4.5 N・m (0.45 kgf・m, 3.3 lb・ft) 3
4 8 7
2 1
5 6
10 N・m (1.0 kgf・m, 7.4 lb・ft)
3.5 N・m (0.35 kgf・m, 2.6 lb・ft)

3.8 N・m (0.38 kgf・m, 2.8 lb・ft)
7
3.8 N・m (0.38 kgf・m, 2.8 lb・ft)
1.8 N・m (0.18 kgf・m, 1.3 lb・ft)
26 N・m (2.6 kgf・m, 19 lb・ft)
* YAMAHA GREASE “F”

Loosen.
Rear brake lock cable adjusting nut Refer to .“REAR BRAKE” on page 4-53.
1 Front brake light switch connector 2 Disconnect. (for XP530E-A/XP530-A)
2 Front brake master cylinder holder 1
3 Front brake master cylinder assembly 1
4 Handlebar switch (right) 1
5 Throttle cable 2 Disconnect.
6 Throttle cable (throttle grip side) 2 Disconnect.
7 Grip end 2
8 Throttle grip 1
4-80
HANDLEBAR
Removing the handlebar switch and throttle grip
FW
D 26 N・m (2.6 kgf・m, 19 lb・ft)
3.5 N・m (0.35 kgf・m, 2.6 lb・ft)
4.5 N・m (0.45 kgf・m, 3.3 lb・ft)
14
16
16
9
11
10 10 N・m (1.0 kgf・m, 7.4 lb・ft)
15 13 3.5 N・m (0.35 kgf・m, 2.6 lb・ft)

17
12 3.8 N・m (0.38 kgf・m, 2.8 lb・ft)
3.8 N・m (0.38 kgf・m, 2.8 lb・ft)

1.8 N・m (0.18 kgf・m, 1.3 lb・ft)
26 N・m (2.6 kgf・m, 19 lb・ft)
* YAMAHA GREASE “F”

9 Rear brake light switch connector 2 Disconnect. (for XP530E-A/XP530-A)
10 Rear brake master cylinder holder 1
11 Bracket 1
12 Rear brake lock lever 1
13 Rear brake lock cable 1 Disconnect.
14 Rear brake master cylinder assembly 1
15 Handlebar switch (left) 1
16 Handlebar switch holder 2
17 Handlebar grip 1
4-81
HANDLEBAR
Removing the handlebar
FW 7 N・m (0.7 kgf・m, 5.2 lb・ft)

D
6
23 N・m (2.3 kgf・m, 17 lb・ft)
3.5 N・m (0.35 kgf・m, 2.6 lb・ft)
5
7
10
8 1 2
3
3
9
4
0.28 N・m (0.028 kgf・m, 0.207 lb・ft)
7 N・m (0.7 kgf・m, 5.2 lb・ft)

34 N・m (3.4 kgf・m, 25 lb・ft)

Handlebar cover/Brake master cylinder/Handle- Refer to “HANDLEBAR” on page 4-79.
bar switch
1 Clamp 2
2 Bracket 1
3 Upper handlebar holder 2
4 Handlebar 1
5 Lower handlebar holder 1
7 Brake hose bracket 1
8 Throttle cable pulley 1
9 Grip cancel switch 1
10 Accelerator position sensor 1
4-82
HANDLEBAR
EAS30203
REMOVING THE HANDLEBAR

EWA13120
WARNING
2. Remove:
• Handlebar grip “1”
TIP
Blow compressed air between the handlebar
EAS30205
and the handlebar grip, and gradually push the
INSTALLING THE HANDLEBAR
grip off the handlebar.
EWA13120
WARNING
2. Install:
• Brake hose bracket
• Lower handlebar holder
• Handlebar “1”
• Upper handlebar holders “2”
• Bracket “3”
3. Remove:
• Handlebar switch (right) “1” Lower handlebar holder nut
• Throttle grip “2” 34 N·m (3.4 kgf·m, 25 lb·ft)
T.
Upper handlebar holder bolt

R.
23 N·m (2.3 kgf·m, 17 lb·ft)

ECA19130
NOTICE
• First, tighten the bolts on the front side of
the upper handlebar holder, and then on
the rear side.
2 • Turn the handlebar all the way to the left
1
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
EAS30204
TIP
CHECKING THE HANDLEBAR Align the punch mark “a” on the handlebar with
1. Check: the right side upper surface of the lower handle-
• Handlebar bar holder.
Bends/cracks/damage  Replace.
EWA13690
WARNING 2
3
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
4-83
HANDLEBAR
3. Install:
• Throttle grip “1”
• Throttle cables 3
• Handlebar switch (right) “2”
• Grip warmer lead holder (for XP530D-A:
Model for routing the grip warmer lead out- d
side the throttle housing)
• Grip end
Handlebar switch screw (right)
3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
Grip end
R.
TIP
26 N·m (2.6 kgf·m, 19 lb·ft) XP530D-A: Model for routing the grip warmer
lead outside the throttle housing
TIP • Insert the projection on the grip warmer lead
• Align the projection “a” on the handlebar switch holder into the hole in the throttle cable holder,
(right) with the hole “b” in the handlebar. and then tighten the screw while pushing the
• There should be 1–3 mm (0.04–0.12 in) of grip warmer lead holder inward “e”.
clearance “c” between the throttle grip and the • Route the grip warmer lead to the front of the
grip end. throttle cable guide “f”.
• Route the grip warmer lead to the inside of the
handlebar cover “g”.
1 • Position the flat side of the grommet against
the handlebar switch “h”.
b h
2
4. Install:
• Front brake master cylinder assembly
Refer to “INSTALLING THE FRONT BRAKE
a MASTER CYLINDER” on page 4-50.
c
5. Install:
• Handlebar switch holder
TIP • Handlebar switch (left)
XP530D-A: Model for routing the grip warmer
lead inside the throttle housing Handlebar switch holder screw
3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
Apply lithium-soap-based grease to the moving
T.
Handlebar switch screw (left)

R.
parts of the grip warmer lead “3” and the inside 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
of the handlebar switch (shaded area “d” in the
illustration). TIP
Align the projection “a” on the handlebar switch
(left) with the hole “b” in the handlebar.
4-84
HANDLEBAR
EWA13700
WARNING
Do not touch the handlebar grip until the rub-
b ber adhesive has fully dried.
TIP
a There should be 1–3 mm (0.04–0.12 in) of clear-
ance “a” between the handlebar grip and the grip
end.
6. Lubricate: a
• Rear brake lock cable
(to cable end)
YAMAHA GREASE “F”
7. Connect: 2 1
• Rear brake lock cable
(to rear brake lock lever) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP
Rotate the lever to the position “a”, and then in- 10.Adjust:
stall the rear brake lock cable. • Throttle grip free play
Refer to “CHECKING THE THROTTLE
GRIP” on page 3-34.
Throttle grip free play
1.0–3.0 mm (0.04–0.12 in)
a
11.Adjust:
EAS32442
ADJUSTING THE ACCELERATOR POSITION

8. Install: SENSOR
• Rear brake master cylinder assembly EWA15960
Refer to “INSTALLING THE REAR BRAKE WARNING

MASTER CYLINDER” on page 4-65. • Handle the accelerator position sensor with
9. Install: special care.
• Handlebar grip “1” • Never subject the accelerator position sen-
• Grip end “2” sor to strong shocks. If the accelerator po-
Grip end sition sensor is dropped, replace it.
26 N·m (2.6 kgf·m, 19 lb·ft) 1. Check:
T.
R.
• Accelerator position sensor

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Refer to “DIAGNOSTIC CODE: SENSOR
a. Apply a thin coat of rubber adhesive onto the OPERATION TABLE” on page 9-12.
end of the left handlebar. 2. Adjust:
b. Slide the handlebar grip over the end of the • Accelerator position sensor angle
left handlebar. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
c. Wipe off any excess rubber adhesive with a a. Temporary tighten the accelerator position
clean rag. sensor screws.
b. Check that the throttle valves are fully closed.
4-85
HANDLEBAR
c. Connect the accelerator position sensor to n. Check the Yamaha diagnostic tool screen
the wire harness. value. If the Yamaha diagnostic tool screen
d. Connect the throttle cables to the throttle ca- value is not 9–23, adjust the accelerator posi-
ble pulley. tion sensor angle.
e. Remove the protective cap “1”, and then con- o. Turn the throttle grip to the fully open position.
nect the Yamaha diagnostic tool to coupler. p. Check the Yamaha diagnostic tool screen
TIP value. If the Yamaha diagnostic tool screen
For information about using the Yamaha diag- value is not 93–109, adjust the accelerator
nostic tool, refer to the operation manual that is position sensor angle.
included with the tool. q. Repeat steps (f) to (p) until the Yamaha diag-
nostic tool screen values are within the spec-
ified ranges.
r. If the Yamaha diagnostic tool screen values
1 are not within the specified ranges after re-
peating steps (f) to (p) several times, replace
the accelerator position sensor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
f. Diagnostic code number “14” is selected.

g. Turn the throttle grip to the fully closed posi-
tion.
h. Adjust the position of the accelerator position
sensor angle so that 11–20 can appear in the
Yamaha diagnostic tool screen.
i. After adjusting the accelerator position sen-
sor angle, tighten the accelerator position
sensor screws “2”.
Accelerator position sensor
screw
T.
3.5 N·m (0.35 kgf·m, 2.6 lb·ft)

R.
2 2
j. Turn the throttle grip to the fully open position.

k. Check the Yamaha diagnostic tool screen
value. If the Yamaha diagnostic tool screen
value is not 95–106, adjust the accelerator
position sensor angle.
l. Select the diagnostic code number “15”.
m. Turn the throttle grip to the fully closed posi-
tion.
4-86
FRONT FORK
EAS20034
FRONT FORK
Removing the front fork legs
30 N・m (3.0 kgf・m, 22 lb・ft)

23 N・m (2.3 kgf・m, 17 lb・ft) 3
4
23 N・m (2.3 kgf・m, 17 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)

the front fork legs.
panel/Meter assembly/Rearview mirror/Bottom 4-1.
side cowling/Side panel/Front cowling assembly
Front wheel Refer to “FRONT WHEEL” on page 4-22.
1 Front fender 1
2 Upper bracket pinch bolt 1 Loosen.
3 Cap bolt 1 Loosen.
4 Lower bracket pinch bolt 2 Loosen.
5 Front fork leg 1
4-87
FRONT FORK
Disassembling the front fork legs
15 N・m (1.5 kgf・m, 11 lb・ft)

15
23 N・m (2.3 kgf・m, 17 lb・ft)
1
2
3
8
4 11
16
5
14
13
12
10
7
9
6 LT
23 N・m (2.3 kgf・m, 17 lb・ft)

the front fork legs.
1 Cap bolt 1
2 O-ring 1
3 Damper rod locknut 1
4 Spacer 1
5 Fork spring 1
6 Damper rod assembly bolt 1
7 Copper washer 1
8 Damper rod assembly 1
9 Dust seal 1
10 Oil seal clip 1
11 Outer tube 1
12 Oil seal 1
13 Washer 1
14 Outer tube bushing 1
15 Inner tube bushing 1
16 Inner tube 1
4-88
FRONT FORK
EAS30206
1. Remove:
REMOVING THE FRONT FORK LEGS • Cap bolt “1”
The following procedure applies to both of the • Spacer “2”
front fork legs. • Damper rod locknut “3”
EWA13120
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
WARNING a. Press down on the spacer with the fork spring
Securely support the vehicle so that there is compressor “4”.
no danger of it falling over. b. Install the rod holder “5” between the damper
rod locknut “3” and the spacer “2”.
TIP
Place the vehicle on a maintenance stand so Fork spring compressor
that the front wheel is elevated. 90890-01441
2. Loosen: YM-01441
• Upper bracket pinch bolt “1” Rod holder
• Cap bolt “2” 90890-01434
• Lower bracket pinch bolts “3” Damper rod holder double ended
EWA13640 YM-01434
WARNING
Before loosening the upper and lower brack- TIP
et pinch bolts, support the front fork leg. Use the side of the rod holder that is marked “B”.
c. Hold the cap bolt “1” and loosen the damper
rod locknut “3”.
1
2
3 2
1 5
4
d. Remove the cap bolt.

e. Remove the rod holder and fork spring com-
pressor.
f. Remove the spacer and damper rod locknut.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3
2. Drain:
• Fork oil
TIP
3. Remove: Stroke the damper rod assembly “1” several
• Front fork leg times while draining the fork oil.
EAS30207
DISASSEMBLING THE FRONT FORK LEGS

front fork legs.
ECA22020
NOTICE
Because the left and right damper rod as-
semblies are different, be sure to install them
in the correct positions.
4-89
FRONT FORK
3. Remove:
• Damper rod assembly bolt
• Damper rod assembly
ECA17401
NOTICE 1
For the damper rod assembly, the right side
is used for the rebound operation and left
side for the compression. Pay attention not
to mistake the right and left.
TIP
• While holding the damper rod assembly with 5. Remove:
the damper rod holder “1”, loosen the damper • Outer tube
rod assembly bolt. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• The left side (for the compression) damper rod a. Hold the front fork leg horizontally.
assembly has the holes “a” of oil path, unlike b. Securely clamp the brake caliper bracket in a
the right side. vise with soft jaws.
c. Separate the outer tube from the inner tube
by pulling the outer tube forcefully but careful-
ly.
A a ECA19880
NOTICE
Excessive force will damage the bushings.
B Damaged bushings must be replaced.
A. Compression side
B. Rebound side
Damper rod holder (ø27)

90890-01423
Damping rod holder
YM-01423
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30208
CHECKING THE FRONT FORK LEGS

1 The following procedure applies to both of the
front fork legs.
1. Check:
• Inner tube “1”
• Outer tube “2”
Bends/damage/scratches  Replace.
EWA13650
WARNING
4. Remove: Do not attempt to straighten a bent inner
• Dust seal tube as this may dangerously weaken it.
• Oil seal clip “1”
(with a flat-head screwdriver)
ECA14180
NOTICE
Do not scratch the inner tube.
4-90
FRONT FORK
EAS30209
ASSEMBLING THE FRONT FORK LEGS

front fork legs.
1 EWA13660
2
WARNING
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor han-
dling and a loss of stability.
2. Measure: TIP
• Spring free length “a” • When assembling the front fork leg, be sure to
Out of specification  Replace. replace the following parts:
–Inner tube bushing
Fork spring free length –Outer tube bushing
297.1 mm (11.70 in) –Oil seal
Limit –Dust seal
291.1 mm (11.46 in)
–Oil seal clip
–O-ring
–Copper washer
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Lubricate:
• Inner tube outer surface
Recommended oil
Suspension oil 01 or equivalent
2. Install:
3. Check: • Dust seal “1” New
• Damper rod assembly “1” • Oil seal clip “2” New
Damage/wear  Replace. • Oil seal “3” New
Obstruction  Blow out all of the oil passag- • Washer “4”
es with compressed air. • Outer tube bushing “5” New
ECA19110
NOTICE • Inner tube bushing “6” New

ECA14220
• The front fork leg has a very sophisticated NOTICE

internal construction, which are particular- Make sure the numbered side of the oil seal
ly sensitive to foreign material. faces up.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma- TIP
terial to enter the front fork. • Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube
with fork oil.
1 • Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.
4-91
FRONT FORK
3 New
2 New
5 New 1 New
4
6 New 2
6. Install:
• Oil seal clip “1”
TIP
Adjust the oil seal clip so that it fits into the outer
tube groove.
1
3. Install:
• Outer tube
(to the inner tube)
4. Install:
• Outer tube bushing “1”
• Washer “2”
7. Install:
(with the fork seal driver “3”)
• Dust seal “1”
Fork seal driver (with the fork seal driver “2”)
90890-01442
Adjustable fork seal driver (36–46 Fork seal driver
mm) 90890-01442
YM-01442 Adjustable fork seal driver (36–46
mm)
YM-01442
3
2
1
5. Install:
• Oil seal “1”
8. Install:
(with the fork seal driver “2”)
• Damper rod assembly “1”
Fork seal driver (to inner tube “2”)
90890-01442 • Copper washer New
Adjustable fork seal driver (36–46 • Damper rod assembly bolt
mm) ECA17401
YM-01442 NOTICE
For the damper rod assembly, the right side
4-92
FRONT FORK
is used for the rebound operation and left

side for the compression. Pay attention not
to mistake the right and left.
2 1
TIP
The left side (for the compression) damper rod
assembly has the holes “a” of oil path, unlike the
right side.
A a 10.Install:
• Rod puller “1”
• Rod puller attachment (M10) “2”
B (onto the damper rod “3”)
Rod puller
90890-01437
Universal damping rod bleeding
tool set
A. Compression side YM-A8703
B. Rebound side Rod puller attachment (M10)
ECA14210 90890-01436
NOTICE Universal damping rod bleeding
Allow the damper rod assembly to slide tool set
YM-A8703
slowly down the inner tube until it protrudes
from the bottom of the inner tube. Be careful
not to damage the inner tube.
11.Fill:
• Front fork leg
9. Tighten: (with the specified amount of the recom-
• Damper rod assembly bolt “1” mended fork oil)
Damper rod assembly bolt Recommended oil
23 N·m (2.3 kgf·m, 17 lb·ft) Yamaha Suspension Oil 01
T.
LOCTITE® Quantity (left)

R.
447.0 cm³ (15.11 US oz, 15.77

TIP Imp.oz)
While holding the damper rod assembly with the Quantity (right)
damper rod holder “2”, tighten the damper rod 437.0 cm³ (14.77 US oz, 15.41
assembly bolt. Imp.oz)
ECA14230
Damper rod holder (ø27) NOTICE

90890-01423 • Be sure to use the recommended fork oil.
Damping rod holder Other oils may have an adverse effect on
YM-01423
front fork performance.
4-93
FRONT FORK
• When disassembling and assembling the (along with the O-ring New )
front fork leg, do not allow any foreign ma- EWA12850
terial to enter the front fork. WARNING

Always use a new O-ring.
12.After filling the front fork leg, slowly stroke the
damper rod assembly “1” up and down (at
least ten times) to distribute the fork oil.
TIP
Be sure to stroke the damper rod assembly 4
slowly because the fork oil may spurt out.
2
1
3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the rod puller and rod puller attach-
ment.
b. Install the damper rod locknut.
c. Install the fork spring and spacer.
TIP
13.Before measuring the fork oil level, wait ten
Install the spring with the smaller diameter “a”
minutes until the oil has settled and the air
facing up “A”.
bubbles have dispersed.
TIP
Be sure to bleed the front fork leg of any residual
air.
14.Measure:
• Front fork leg oil level “a”
(from the top of the outer tube, with the outer
tube fully compressed and without the fork
spring)
Out of specification  Correct.
Level (left) d. Press down in the spacer with the fork spring
114 mm (4.5 in) compressor “5”.
Level (right) e. Pull up the rod puller and install the rod holder
118 mm (4.6 in) “6” between the damper rod locknut “1” and
the spacer “3”.
TIP
Use the side of the rod holder that is marked “B”.

90890-01441
YM-01441
Rod holder
90890-01434
Damper rod holder double ended
15.Install: YM-01434
• Damper rod locknut “1”
• Fork spring “2”
• Spacer “3”
• Cap bolt “4”
4-94
FRONT FORK
bracket pinch bolts.

TIP
Make sure the outer tube is flush with the top of
the upper bracket.
1 6
3 2. Tighten:
5 • Lower bracket pinch bolts “1”
• Cap bolt “2”
• Upper bracket pinch bolt “3”
Lower bracket pinch bolt
f. Remove the rod puller and the rod puller at- 23 N·m (2.3 kgf·m, 17 lb·ft)
T.
Front fork cap bolt
R.
tachment.
g. Install the damper rod locknut “1” onto the 23 N·m (2.3 kgf·m, 17 lb·ft)
damper rod and turn it until it stops. Upper bracket pinch bolt
30 N·m (3.0 kgf·m, 22 lb·ft)
3
h. Install the cap bolt “4”, and then tighten the
damper rod locknut “1” until it contacts the
bolt.
4
1
i. Hold the cap bolt and tighten the damper rod

locknut to specification.
Damper rod locknut
15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
j. Remove the rod holder and fork spring com-

pressor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30210
INSTALLING THE FRONT FORK LEGS

front fork legs.
1. Install:
• Front fork leg
Temporarily tighten the upper and lower
4-95
STEERING HEAD
EAS20035
STEERING HEAD
Removing the lower bracket
1st 52 N・m (5.2 kgf・m, 38 lb・ft) 130 N・m (13 kgf・m, 96 lb・ft)
2nd 16 N・m (1.6 kgf・m, 12 lb・ft)
2 LT
4 3
LT
7 5
6
FWD
LT
7 N・m (0.7 kgf・m, 5.2 lb・ft)
*Loosen the lower ring nut completely, and then tighten it to specification.
Handlebar cover/Handlebar/Lower handlebar Refer to “HANDLEBAR” on page 4-79.
holder
1 Stay 2
2 Steering stem nut 1
3 Upper bracket 1
4 Lock washer 1
5 Upper ring nut 1
6 Rubber washer 1
7 Lower ring nut 1
4-96
STEERING HEAD
Removing the lower bracket

1st 52 N・m (5.2 kgf・m, 38 lb・ft) 130 N・m (13 kgf・m, 96 lb・ft)
2nd 16 N・m (1.6 kgf・m, 12 lb・ft)
LT
11
13
LT
12
9 14
8
10
15
FWD
LT
7 N・m (0.7 kgf・m, 5.2 lb・ft)
*Loosen the lower ring nut completely, and then tighten it to specification.
8 Lower bracket 1
9 Upper bearing cover 1
10 Upper bearing 1
11 Lower bearing 1
12 Dust seal 1
13 Steering lock unit coupler 1 Disconnect.
14 Steering lock unit 1
15 Stay 1
4-97
STEERING HEAD
EAS30213
REMOVING THE LOWER BRACKET

EWA13120
WARNING
2. Remove:
• Upper ring nut
• Rubber washer
• Lower ring nut “1” 3. Replace:
• Lower bracket • Bearings
TIP • Bearing races
Remove the upper ring nut and lower ring nut ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
with the steering nut wrench “2”. a. Remove the bearing races from the steering
EWA13730 head pipe “1” with a long rod “2” and hammer.
WARNING b. Remove the bearing race from the lower
Securely support the lower bracket so that bracket “3” with a floor chisel “4” and ham-
there is no danger of it falling. mer.
c. Install a new rubber seal and new bearing
Steering nut wrench races.
90890-01403 ECA14270
Exhaust flange nut wrench NOTICE

YU-A9472 If the bearing race is not installed properly,
the steering head pipe could be damaged.
TIP
• Always replace the bearings and bearing races
as a set.
• Whenever the steering head is disassembled,
replace the dust seal.
EAS30214
CHECKING THE STEERING HEAD

1. Wash:
• Bearings
• Bearing races
Recommended cleaning solvent
Kerosene
2. Check:
• Bearings “1”
• Bearing races “2”
Damage/pitting  Replace.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-98
STEERING HEAD
4. Check:
• Upper bracket
• Lower bracket
(along with the steering stem)
Bends/cracks/damage  Replace.
EAS30216
INSTALLING THE STEERING HEAD

1. Lubricate:
• Upper bearing
• Lower bearing
2. Install:
• Lower ring nut “1”
• Rubber washer “2”
• Upper ring nut “3”
• Lock washer “4”
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-24.
1
2
3. Install:
• Upper bracket
• Washer
• Steering stem nut
TIP
Temporarily tighten the steering stem nut.
4. Install:
• Front fork legs
Refer to “FRONT FORK” on page 4-87.
TIP
Temporarily tighten the upper and lower bracket
pinch bolts.
5. Tighten:
• Steering stem nut
Steering stem nut
130 N·m (13 kgf·m, 96 lb·ft)
T.
R.
4-99
BELT DRIVE
EAS20039
BELT DRIVE
Removing the drive belt
FW
D
48 N・m (4.8 kgf・m, 35 lb・ft)
8
7
48 N・m (4.8 kgf・m, 35 lb・ft)

1
9
6
5
4
2
10 N・m (1.0 kgf・m, 7.4 lb・ft)
* Filling the YAMAHA GREASE “J” (Shell Alvania EP Grease R0®).

Rear wheel Refer to “REAR WHEEL” on page 4-31.
1 Drive pulley cover 1
2 Dust cover 1
3 Holder 1
4 Circlip 1
5 Bearing 1
6 Oil seal 1
7 Drive pulley 1
8 Collar 2
9 Drive belt 1
4-100
BELT DRIVE
EAS30236 EAS31586
CHECKING THE DRIVE BELT INSTALLING THE DRIVE BELT AND DRIVE
1. Check: PULLEY
• Drive belt 1. Install:
Refer to “CHECKING THE DRIVE BELT” on • Drive belt
page 3-21. ECA22720
ECA26680 NOTICE
NOTICE Align the mark of the drive belt with the prog-
• To protect the drive belt from damage, han- ress direction “A”.
dle it with care. Do not twist the drive belt when installing it.
• The drive belt can not be bent smaller than
90 mm (3.54 in) “a”.
• The removed drive belt can not be twisted
inside out.
BC3 -4 6 2 4 1 -0 1 DO NOT BEND
A
BC3 -4 6 2 4 1 -0 1 DO NOT BEND
2. Install:
• Drive pulley assembly
• Drive pulley assembly bolt
3. Tighten:
2. Check: • Drive pulley assembly bolt
• Drive pulley “1” TIP
• Rear wheel pulley “2” Tighten the drive pulley assembly bolts in the fol-
Bent teeth  Replace the drive belt and pul- lowing order, bolt “1”, bolts “2”, and bolts “3”.
leys as a set.
Drive pulley assembly bolt
1 2 48 N·m (4.8 kgf·m, 35 lb·ft)
T.
R.
2
1
2 3
3. Check:
• Holder “1”
4. Adjust:
• Drive belt tension
1 3-22.
4-101
REAR SHOCK ABSORBER ASSEMBLY
EAS20036

Removing the rear shock absorber assembly
2 1
3
50 N・m (5.0 kgf・m, 37 lb・ft)
1
75 N・m (7.5 kgf・m, 55 lb・ft)
2 10
9 10
50 N・m (5.0 kgf・m, 37 lb・ft)
7 11
8
12 5 11
5
6
13
12
8 7
13
4

1 Relay arm nut/Relay arm bolt 1/1
Rear shock absorber assembly lower nut/Rear
2 1/1
shock absorber assembly lower bolt
3 Collar 1
4 Collar 1
Rear shock absorber assembly upper
5 nut/Washer/Rear shock absorber assembly 1/2/1
upper bolt
6 Rear shock absorber assembly 1
7 Connecting arm bolt/Connecting arm nut 1/1
8 Connecting arm 2
9 Relay arm 1
10 Collar/Oil seal/Bearing 1/2/1
13 Oil seal/Bearing 4/2
4-102
EAS30826
HANDLING THE REAR SHOCK ABSORBER

EWA13740 50 mm (1.97 in)
WARNING
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make sure
you understand the following information.
The manufacturer cannot be held responsi-
ble for property damage or personal injury
that may result from improper handling of
the rear shock absorber. A. XP530E-A/XP530-A
• Do not tamper or attempt to open the rear B. XP530D-A
shock absorber.
EAS30219
• Do not subject the rear shock absorber to
REMOVING THE REAR SHOCK ABSORBER
an open flame or any other source of high
ASSEMBLY
heat. High heat can cause an explosion due
to excessive gas pressure. EWA13120
• Do not deform or damage the rear shock WARNING

absorber in any way. Rear shock absorber Securely support the vehicle so that there is
damage will result in poor damping perfor- no danger of it falling over.
mance.
TIP
EAS30729 Place the vehicle on a maintenance stand so
DISPOSING OF A REAR SHOCK ABSORBER that the rear wheel is elevated.
1. Gas pressure must be released before dis-
2. Remove:
posing of a rear shock absorber. To release
• Relay arm bolt “1”
the gas pressure, drill a 2–3 mm (0.08–0.12
• Relay arm nut
in) hole through the rear shock absorber as
• Rear shock absorber assembly lower bolt “2”
shown.
EWA13760 • Rear shock absorber assembly lower nut
WARNING • Collar “3”
Wear eye protection to prevent eye damage TIP
from released gas or metal chips. • When removing the bolt, hold the swingarm so
that it does not drop down.
TIP • Pull out the collar “3” from the right side of the
Drill a hole at a point 50 mm (1.97 in) from the vehicle.
center of the installation hole.
50 mm (1.97 in) 4
2
3
3. Remove:
• Rear shock absorber assembly “4”
4-103
EAS30220
TIP
CHECKING THE REAR SHOCK ABSORBER • When installing the oil seals “2” to the connect-
ASSEMBLY ing arms “3”, face the character stamp of the oil
1. Check: seals outside.
• Rear shock absorber rod • Install the bearing to the connecting arm by
Bends/damage  Replace the rear shock pressing the character stamped side.
absorber assembly.
• Rear shock absorber assembly
Installed depth “a”
Gas leaks/oil leaks  Replace the rear shock
7 mm (0.28 in)
absorber assembly. Installed depth “b”
• Spring 0.5–1.5 mm (0.02–0.06 in)
Damage/wear  Replace the rear shock ab- Installed depth “c”
sorber assembly. 2.5–3.5 mm (0.10–0.14 in)
• Bearing
• Bolts
Bends/damage/wear  Replace.
EAS30221
CHECKING THE CONNECTING ARM AND 4

RELAY ARM 2
1. Check:
• Connecting arms “1” 1 3
• Relay arm “2”
2
5
1 2 b
2
1 3
2 a
4 c
2. Check:
• Bearings 4. Collar
• Oil seals 5. Rear shock absorber assembly
Damage/pitting  Replace. A. Left side
3. Check: B. Right side
• Collars
Damage/scratches  Replace.
EAS30222
INSTALLING THE RELAY ARM

EAS32420 1. Lubricate:
ASSEMBLING THE CONNECTING ARM • Collars
1. Lubricate: • Oil seals
• Collars
• Oil seals Recommended lubricant
Lithium-soap-based grease 2. Install:
• Bearings “1”
2. Install: (to the relay arm)
• Bearings “1” • Oil seals “2” New
• Oil seals “2” New (to the relay arm)
4-104
Installed depth “a” a

6.5 mm (0.26 in)
Installed depth “b”
6 mm (0.24 in)
Installed depth “c”
1.0–2.0 mm (0.04–0.08 in)
TIP
• When installing the oil seals “2” to the relay
arm, face the character stamp of the oil seals b
outside. EAS30225
• Press in the oil seal so it does not protrude INSTALLING THE REAR SHOCK
from the end surface of the relay arm. ABSORBER ASSEMBLY
• Install the connecting arm so that the stamp 1. Install:
mark “B67” is facing outward. The stamp mark • Rear shock absorber assembly
can be facing either up or down. TIP
• Install the rear shock absorber assembly lower
a bolt and relay arm bolt from the right.
c • Install the rear shock absorber assembly with
5 1 5 the swingarm down.
2. Tighten:
• Rear shock absorber assembly lower nut
b • Relay arm nut
3 2 c
Rear shock absorber assembly
lower nut
T.
75 N·m (7.5 kgf·m, 55 lb·ft)

R.
Relay arm nut

50 N·m (5.0 kgf·m, 37 lb·ft)
4 1 1 4
2 2
c
1 a
3. Relay arm
4. Connecting arm
5. Rear shock absorber assembly
A. Left side
B. Right side
TIP
• Install the rear shock absorber assembly upper
bolt and connecting arm bolt from the left.
• Install the relay arm so that stamped mark “a”
is positioned as shown in the illustration.
• Install the rear shock absorber assembly so
that the label is facing downward.
• Install the rear shock absorber assembly so
that the rebound damping adjusting screw “b”
is facing downward. (for XP530D-A)
4-105
SWINGARM
EAS20037
SWINGARM
Removing the swingarm
10 30 N・m (3.0 kgf・m, 22 lb・ft)
7 N・m (0.7 kgf・m, 5.2 lb・ft)

40 N・m (4.0 kgf・m, 30 lb・ft)
6 N・m (0.6 kgf・m, 4.4 lb・ft)
100 N・m (10 kgf・m, 74 lb・ft)

10 N・m (1.0 kgf・m, 7.4 lb・ft)
7
6 2
5
1
LT
4
6
10 N・m (1.0 kgf・m, 7.4 lb・ft) D
40 N・m (4.0 kgf・m, 30 lb・ft)
FW

Refer to “REAR SHOCK ABSORBER
Rear shock absorber assembly ASSEMBLY” on page 4-102.
Drive belt Refer to “BELT DRIVE” on page 4-100.
1 Holder 1
2 Holder 1
3 Drive belt inner guard 1
4 Swingarm (left) 1
5 Swingarm (right) 1
6 Dowel pin 2
7 Pivot shaft 1
8 Oil seal 1
9 Oil seal 1
10 Outer race 1
4-106
SWINGARM
Removing the swingarm

30 N・m (3.0 kgf・m, 22 lb・ft)
13 16 15 14
11 12
7 N・m (0.7 kgf・m, 5.2 lb・ft)

40 N・m (4.0 kgf・m, 30 lb・ft)
6 N・m (0.6 kgf・m, 4.4 lb・ft)
100 N・m (10 kgf・m, 74 lb・ft)

10 N・m (1.0 kgf・m, 7.4 lb・ft)
LT
10 N・m (1.0 kgf・m, 7.4 lb・ft) D

40 N・m (4.0 kgf・m, 30 lb・ft)
FW

11 Bearing 1
12 Bearing housing 1
13 O-ring 1
14 Collar 1
15 Oil seal 1
16 Bearing 1
4-107
SWINGARM
EAS30226 EAS30227
REMOVING THE SWINGARM CHECKING THE SWINGARM

1. Stand the vehicle on a level surface. 1. Check:
EWA13120
• Swingarm (left) “1”
WARNING • Swingarm (right) “2”
Securely support the vehicle so that there is Bends/cracks/damage  Replace.
TIP
Place the vehicle on a maintenance stand so
that the rear wheel is elevated.
2. Measure:
• Swingarm side play
• Swingarm vertical movement 1 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the tightening torque of the drive
pulley assembly bolts, swingarm bolts and
pivot shaft nut. 2. Check:
• Drive pulley assembly bolts
Drive pulley assembly bolt • Swingarm bolts
48 N·m (4.8 kgf·m, 35 lb·ft) Damage/wear  Replace.
T.
Swingarm bolt
R.
40 N·m (4.0 kgf·m, 30 lb·ft) EAS30228
Pivot shaft INSTALLING THE SWINGARM

6 N·m (0.6 kgf·m, 4.4 lb·ft) 1. Lubricate:
Pivot shaft nut • Taper roller bearing
100 N·m (10 kgf·m, 74 lb·ft) TIP
Lubricate the space in the swingarm with lithium-
b. Check the swingarm side play “A” by moving soap-based grease before installing the taper
the swingarm from side-to-side. roller bearing.
c. If the swingarm has side-to-side play, check
the bearings.
d. Check the swingarm vertical movement “B”
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the bearings.
2. Install:
• Pivot shaft “1”
• Washer “2”
• Pivot shaft nut “3”
TIP
Install the parts to the swingarm “4” temporarily,
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
making sure that the portion “a” of the pivot shaft
3. Remove: does not protrude past the swingarm surface “b”.
• Drive belt
4. Remove:
• Swingarm bolt
• Pivot shaft nut
4-108
SWINGARM
3. Install:
• Dowel pins
• Swingarm
• Swingarm bolts
• Drive pulley assembly
Swingarm bolt
40 N·m (4.0 kgf·m, 30 lb·ft)
T.
Drive pulley assembly bolt

R.
48 N·m (4.8 kgf·m, 35 lb·ft)
4. Tighten:
• Pivot shaft
• Pivot shaft nut
Pivot shaft
6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
Pivot shaft nut

R.
100 N·m (10 kgf·m, 74 lb·ft)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. With your fingers, screw in the pivot shaft until
it touches the collar, and then tighten the piv-
ot shaft to the specified torque.
b. Tighten the pivot shaft nut to the specified
torque.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-109
ENGINE
ENGINE INSPECTION .....................................................................................5-1

MEASURE THE COMPRESSION PRESSURE.........................................5-1
ENGINE REMOVAL..........................................................................................5-2
INSTALLING THE ENGINE........................................................................5-6
1
2
CAMSHAFTS....................................................................................................5-7
REMOVING THE CAMSHAFTS.................................................................5-9
CHECKING THE CAMSHAFTS ...............................................................5-10
CHECKING THE CAMSHAFT SPROCKETS ..........................................5-11
CHECKING THE TIMING CHAIN GUIDES..............................................5-11
CHECKING THE TIMING CHAIN TENSIONER.......................................5-11
INSTALLING THE CAMSHAFTS .............................................................5-12
3
CYLINDER HEAD...........................................................................................5-15
REMOVING THE CYLINDER HEAD........................................................5-16
4
CHECKING THE CYLINDER HEAD ........................................................5-16
INSTALLING THE CYLINDER HEAD ......................................................5-16
VALVES AND VALVE SPRINGS ....................................................................5-18

REMOVING THE VALVES.......................................................................5-19
CHECKING THE VALVES AND VALVE GUIDES ...................................5-19
CHECKING THE VALVE SEATS .............................................................5-21
CHECKING THE VALVE SPRINGS.........................................................5-22
5
CHECKING THE VALVE LIFTERS ..........................................................5-23
INSTALLING THE VALVES .....................................................................5-23
CYLINDER AND PISTONS ............................................................................5-25

REMOVING THE PISTON .......................................................................5-26
6
CHECKING THE CYLINDERS AND PISTONS .......................................5-26
CHECKING THE PISTON RINGS............................................................5-27
CHECKING THE PISTON PINS...............................................................5-28
INSTALLING THE PISTON AND CYLINDER ..........................................5-28 7
ELECTRIC STARTER.....................................................................................5-30
CHECKING THE STARTER MOTOR ......................................................5-32
ASSEMBLING THE STARTER MOTOR..................................................5-33
INSTALLING THE STARTER MOTOR ....................................................5-33 8
V-BELT AUTOMATIC TRANSMISSION .........................................................5-34
9
REMOVING THE PRIMARY SHEAVE AND SECONDARY SHEAVE.....5-38
DISASSEMBLY THE SECONDARY SHEAVE.........................................5-38
CHECKING THE V-BELT.........................................................................5-39
CHECKING THE PRIMARY SHEAVE .....................................................5-39
CHECKING THE V-BELT CASE AIR DUCT ............................................5-39
CHECKING THE PRIMARY SHEAVE WEIGHTS....................................5-39
CHECKING THE SLIDERS ......................................................................5-39
CHECKING THE SECONDARY SHEAVE ...............................................5-39
ASSEMBLING THE PRIMARY SHEAVE .................................................5-40
ASSEMBLING THE SECONDARY SHEAVE...........................................5-40
INSTALLING THE PRIMARY SHEAVE ASSEMBLY, SECONDARY
SHEAVE ASSEMBLY AND V-BELT .......................................................5-41
INSTALLING THE V-BELT CASE ............................................................5-43
GENERATOR AND STARTER CLUTCH .......................................................5-44

REMOVING THE GENERATOR ..............................................................5-47
REMOVING THE STARTER CLUTCH ....................................................5-47
CHECKING THE STARTER CLUTCH .....................................................5-47
CHECKING THE OIL STRAINER ............................................................5-48
ASSEMBLING THE OIL TANK.................................................................5-48
INSTALLING THE STARTER CLUTCH ...................................................5-48
INSTALLING THE GENERATOR.............................................................5-49
CLUTCH .........................................................................................................5-51
REMOVING THE CLUTCH ......................................................................5-54
DISASSEMBLING THE CLUTCH ............................................................5-54
CHECKING THE FRICTION PLATES......................................................5-55
CHECKING THE CLUTCH PLATES ........................................................5-55
CHECKING THE CLUTCH DAMPER SPRINGS .....................................5-55
CHECKING THE CLUTCH SPRING PLATE............................................5-55
CHECKING THE CLUTCH SPRINGS......................................................5-56
CHECKING THE CLUTCH HOUSING .....................................................5-56
CHECKING THE CLUTCH BOSS............................................................5-56
CHECKING THE PRESSURE PLATE AND THRUST PLATE.................5-56
ASSEMBLING THE CLUTCH ..................................................................5-56
INSTALLING THE CLUTCH.....................................................................5-58
OIL PUMP.......................................................................................................5-59
CHECKING THE OIL PUMP ....................................................................5-61
CHECKING THE RELIEF VALVE ............................................................5-61
CHECKING THE OIL PIPES ....................................................................5-61
CHECKING THE OIL PUMP DRIVE CHAIN ............................................5-61
ASSEMBLING THE OIL PUMP................................................................5-61
INSTALLING THE OIL PUMP ..................................................................5-61
CRANKCASE .................................................................................................5-62
DISASSEMBLING THE CRANKCASE.....................................................5-65
CHECKING THE CRANKCASE ...............................................................5-65
CHECKING THE TIMING CHAIN.............................................................5-65
ASSEMBLING THE CRANKCASE...........................................................5-65
CRANKSHAFT ...............................................................................................5-67
REMOVING THE CONNECTING RODS .................................................5-69
REMOVING THE CRANKSHAFT JOURNAL BEARINGS .......................5-69
CHECKING THE CRANKSHAFT AND CONNECTING RODS................5-69
INSTALLING THE CRANKSHAFT JOURNAL BEARINGS......................5-73
INSTALLING THE CONNECTING RODS................................................5-73
INSTALLING THE CRANKSHAFT ASSEMBLY.......................................5-75
TRANSMISSION.............................................................................................5-77
CHECKING THE TRANSMISSION ..........................................................5-78
ENGINE INSPECTION
EAS20041
Out of specification  Refer to steps (c) and
ENGINE INSPECTION (d).
EAS30249
Compression pressure
MEASURE THE COMPRESSION PRESSURE 1696–2184 kPa/470 r/min (17.0–
The following procedure applies to all of the cyl- 21.8 kgf/cm²/470 r/min, 241.3–
inders. 310.6 psi/470 r/min)
TIP
Insufficient compression pressure will result in a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
loss of performance. a. Push the ON/start switch.
1. Measure: b. With the throttle wide open, crank the engine
• Valve clearance until the reading on the compression gauge
Out of specification  Adjust. stabilizes.
Refer to “ADJUSTING THE VALVE CLEAR- TIP
ANCE” on page 3-5. The difference in compression pressure be-
2. Start the engine, warm it up for several min- tween cylinders should not exceed 100 kPa (1
utes, and then turn it off. kgf/cm², 14 psi).
3. Remove: c. If the compression pressure is above the
• Bottom side cowling maximum specification, check the cylinder
• Side panel head, valve surfaces and piston crown for
• Radiator cover carbon deposits.
Refer to “GENERAL CHASSIS (1)” on page Carbon deposits  Eliminate.
4-1. d. If the compression pressure is below the min-
4. Disconnect: imum specification, pour a teaspoonful of en-
• Spark plug caps gine oil into the spark plug bore and measure
5. Remove: again.
• Spark plugs Refer to the following table.
ECA13340
NOTICE Compression pressure (with oil applied into the

cylinder)
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumulat- Reading Diagnosis
ed in the spark plug wells to prevent it from Higher than without oil Piston ring(s) wear or
falling into the cylinders. damage  Replace.
6. Install: Same as without oil Piston, valves or cylin-
• Compression gauge “1” der head gasket possi-
bly defective 
Compression gauge Replace.
90890-03081 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Engine compression tester
YU-33223 8. Install:
• Spark plugs
Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
9. Connect:
• Spark plug caps
10.Install:
1 • Radiator cover
• Side panel
7. Measure: 4-1.
• Compression pressure
5-1
ENGINE REMOVAL
EAS20042
ENGINE REMOVAL
Removing the exhaust assembly
8 N・m (0.8 kgf・m, 5.9 lb・ft)
7 N・m (0.7 kgf・m, 5.2 lb・ft)
LT
7
8
LT
6
1
LT
5
8 N・m (0.8 kgf・m, 5.9 lb・ft) 2

31 N・m (3.1 kgf・m, 23 lb・ft) 3
LT
4
25 N・m (2.5 kgf・m, 18 lb・ft)
FW
7 N・m (0.7 kgf・m, 5.2 lb・ft) D
20 N・m (2.0 kgf・m, 15 lb・ft)

cowling 4-1.
1 O2 sensor coupler 1 Disconnect.
2 O2 sensor 1
3 Exhaust assembly 1
4 Gasket 2
5 Front muffler protector 1
6 Muffler protector 1
7 Muffler end 1
8 Muffler end bracket 1
5-2
ENGINE REMOVAL
Disconnecting the leads

10 N・m (1.0 kgf・m, 7.4 lb・ft)
10
9
7 N・m (0.7 kgf・m, 5.2 lb・ft)

7
5
4
6
10
2
1

Center cover/Fuel tank cover assembly/Side
cover/Footboard/Rear cowling/Mudguard Refer to “GENERAL CHASSIS (2)” on page
assembly/Rear cowling assembly/Seat assem- 4-11.
bly/Storage box
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-28.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-31.
Exhaust assembly Refer to “ENGINE REMOVAL” on page 5-2.
Fuel tank/Rollover valve Refer to “FUEL TANK” on page 7-1.
Front fender Refer to “FRONT FORK” on page 4-87.
Refer to “REAR SHOCK ABSORBER
Rear shock absorber assembly ASSEMBLY” on page 4-102.
5-3
ENGINE REMOVAL
Disconnecting the leads

10 N・m (1.0 kgf・m, 7.4 lb・ft)
10
9
7 N・m (0.7 kgf・m, 5.2 lb・ft)

7
5
4
6
10
2
1

Swingarm Refer to “SWINGARM” on page 4-106.
Air filter case/Throttle body assembly/Intake Refer to “THROTTLE BODY” on page 7-5.
manifold
V-belt case air filter element (left)/Water pump Refer to “WATER PUMP” on page 6-9.
inlet pipe
V-belt case air duct SION” on page 5-34.
Oil cooler outlet hose Refer to “OIL COOLER” on page 6-5.
Cooling system air bleed hose/Thermostat out- Refer to “THERMOSTAT” on page 6-7.
let hose
1 Spark plug cap 2 Disconnect.
2 Sidestand switch coupler 1 Disconnect.
3 Centerstand lock solenoid coupler 1 Disconnect.
4 Stator coil coupler 1 Disconnect.
5 Crankshaft position sensor coupler 1 Disconnect.
6 Starter motor lead 1 Disconnect.
7 Coolant temperature sensor coupler 1 Disconnect.
9 Cable guide 1
10 Wire harness 1
5-4
ENGINE REMOVAL
Removing the engine

83 N・m (8.3 kgf・m, 61 lb・ft) 1 2
LT LT
LT 2
5 3
LT
4
9
105 N・m (10.5 kgf・m, 77 lb・ft)
70 N・m (7.0 kgf・m, 52 lb・ft)

8
9
LT
7
6 LT
6 77 N・m (7.7 kgf・m, 57 lb・ft)

10
78 N・m (7.8 kgf・m, 58 lb・ft)
FW
D

1 Damper 2
2 Rear frame bolt 2
3 Engine mounting nut (rear side) 1
4 Engine mounting bolt (rear side) 1
5 Rear frame 2
6 Engine mounting bolt (front left lower side) 2
7 Sidestand 1
8 Engine mounting bolt (front right lower side) 1
9 Engine mounting bolt (front upper side) 2
10 Engine 1
5-5
ENGINE REMOVAL
EAS30251
INSTALLING THE ENGINE

1. Install: 5
• All removed parts
TIP 5 4
• Apply locking agent (LOCTITE®) to engine
mounting bolt (front upper side) “1”, engine
mounting bolt (front right lower side) “2”, en- 1
gine mounting bolts (front left lower side) “3”,
and rear frame bolts “5”. 1 2
• For installation, reverse the removal proce-
dure.
• Do not fully tighten the bolts and nuts.
2. Tighten: 3
• Engine mounting bolts (front upper side) “1”
• Engine mounting bolt (front right lower side)
“2”
• Engine mounting bolts (front left lower side)
“3”
• Engine mounting nut (rear side) “4”
• Rear frame bolts “5”
TIP
When tightening the engine mounting nuts and
engine mounting bolts, do not apply an upward
load to the frame, such as supporting the area
around steering head of the frame upwards. Al-
so, do not apply an upward or downward load on
the rear frame, such as supporting the rear end
of the rear frame upwards or pushing it down-
wards.
Engine mounting bolt (front up-

per side)
T.
77 N·m (7.7 kgf·m, 57 lb·ft)

R.
LOCTITE®
Engine mounting bolt (front right
lower side)
70 N·m (7.0 kgf·m, 52 lb·ft)
LOCTITE®
Engine mounting bolt (front left
lower side)
78 N·m (7.8 kgf·m, 58 lb·ft)
LOCTITE®
Engine mounting nut (rear side)
105 N·m (10.5 kgf·m, 77 lb·ft)
Rear frame bolt
83 N·m (8.3 kgf·m, 61 lb·ft)
LOCTITE®
5-6
CAMSHAFTS
EAS20043
CAMSHAFTS
Removing the cylinder head cover
10 N・m (1.0 kgf・m, 7.4 lb・ft)

13 N・m (1.3 kgf・m, 9.6 lb・ft)

Drain.
page 3-28.
Air filter case Refer to “THROTTLE BODY” on page 7-5.
1 Spark plug cap 2 Disconnect.
2 Spark plug 2
3 Cylinder head breather hose 1
4 Cylinder head cover 1
5 Cylinder head cover gasket 1
6 Dowel pin 2
7 Gasket 2
8 Timing chain guide (upper side) 1
5-7
CAMSHAFTS
Removing the camshafts
10 N・m (1.0 kgf・m, 7.4 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)
7
8
5
9
12 N・m (1.2 kgf・m, 8.9 lb・ft)
6
8 N・m (0.8 kgf・m, 5.9 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)

Crankshaft end access cover SION” on page 5-34.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Intake manifold Refer to “THROTTLE BODY” on page 7-5.
Cylinder head cover Refer to “CAMSHAFTS” on page 5-7.
1 Timing mark accessing plug 1
2 Timing chain tensioner rod accessing plug 1
3 Timing chain tensioner 1
4 Timing chain tensioner gasket 1
5 Intake camshaft cap 1
6 Exhaust camshaft cap 1
TIP
7 Dowel pin 4 During removal, the dowel pins may still be
connected to the camshaft caps.
8 Intake camshaft 1
9 Exhaust camshaft 1
5-8
CAMSHAFTS
EAS30256
2. Remove:
REMOVING THE CAMSHAFTS • Timing chain tensioner “1”
1. Align: • Timing chain tensioner gasket
• “I” mark “a” on the generator rotor
(with the stationary pointer “b” on the genera- 1
tor cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
3. Remove:
• Intake camshaft cap “1”
• Exhaust camshaft cap “2”
• Dowel pins
ECA13720
b. When piston #1 is at TDC on the compres- NOTICE

sion stroke, align the “I” mark “a” on the gen- To prevent damage to the cylinder head,
erator rotor with the stationary pointer “b” on camshafts or camshaft caps, loosen the
the generator cover. camshaft cap bolts in stages and in a criss-
TIP cross pattern, working from the outside in.
• TDC on the compression stroke can be found
when the cylinder #1 camshaft lobes are
turned away from each other.
• In order to be sure that the piston is at TDC, the
alignment marks “c” on the intake camshaft 1
sprocket and the alignment marks “d” on the
exhaust camshaft sprocket must align with the
cylinder head mating surface as shown in the 2
illustration.
b 4. Remove:
• Intake camshaft “1”
• Exhaust camshaft “2”
TIP
To prevent the timing chain from falling into the
a
crankcase, fasten with a wire “3”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-9
CAMSHAFTS
EAS30257
4. Measure:
CHECKING THE CAMSHAFTS • Camshaft-journal-to-camshaft-cap clearance
1. Check: Out of specification  Measure the camshaft
• Camshaft lobes journal diameter.
Blue discoloration/pitting/scratches  Re- Camshaft-journal-to-camshaft-
place the camshaft. cap clearance
2. Measure: 0.028–0.062 mm (0.0011–0.0024
• Camshaft lobe dimensions “a” in)
Out of specification  Replace the camshaft. Limit
0.080 mm (0.0032 in)
Camshaft lobe dimensions
Lobe height (Intake) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
32.490–32.590 mm (1.2791–
a. Install the camshaft into the cylinder head
1.2831 in)
Limit (without the dowel pins and camshaft caps).
32.390 mm (1.2752 in) b. Position a strip of Plastigauge® “1” onto the
Lobe height (Exhaust) camshaft journal as shown.
32.690–32.790 mm (1.2870–
1.2909 in) 1
Limit
32.590 mm (1.2831 in)
c. Install the dowel pins and camshaft caps.

TIP
• When tightening the camshaft cap, tighten the
four bolts on the both ends of the cap tempo-
3. Measure: rarily to lower the entire cap, while paying at-
• Camshaft runout tention not to twist the dowel pins and camshaft
Out of specification  Replace. journal. After the camshaft cap touches the cyl-
inder head, tighten the two bolts in the middle
Camshaft runout limit to the specified torque and then the remaining
0.030 mm (0.0012 in) four bolts to the specified torque.
• To prevent the camshaft cap from cracking,
tighten the camshaft cap carefully by tapping
the camshaft using a soft-face hammer (both
for temporary and final tightening).
• Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance
5-10
CAMSHAFTS
with the Plastigauge®.
Camshaft cap bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
d. Remove the camshaft caps and then mea-

sure the width of the Plastigauge® “1”.
a. 1/4 tooth
b. Correct
1. Timing chain
2. Camshaft sprocket
EAS30265
CHECKING THE TIMING CHAIN GUIDES

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. Check:
• Timing chain guide (intake side) “1”
5. Measure: • Timing chain guide (exhaust side) “2”
• Camshaft journal diameter “a” • Timing chain guide (upper side) “3”
Out of specification  Replace the camshaft. Damage/wear  Replace the defective
Within specification  Replace the cylinder part(s).
head and the camshaft caps as a set.
Camshaft journal diameter
22.959–22.972 mm (0.9039–
0.9044 in)
EAS30266
CHECKING THE TIMING CHAIN TENSIONER

1. Check:
• Timing chain tensioner
EAS30936 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE CAMSHAFT SPROCKETS a. Push the timing chain tensioner rod “1” into
The following procedure applies to both of the the timing chain tensioner housing by hand.
camshaft sprockets. TIP
1. Check: While pushing the timing chain tensioner rod “a”,
• Camshaft sprocket turn it clockwise “b” with the timing chain ten-
More than 1/4 tooth wear “a” Replace the sioner body “2” until it stops.
camshafts and the timing chain as a set.
5-11
CAMSHAFTS
2
b
2
1
a
1
b. Lock the timing chain tensioner rod by setting

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
the circlip “3” to groove “4” while pushing the
a. Turn the crankshaft clockwise.
timing chain tensioner rod.
c. Push the timing chain tensioner rod “c”. b. When piston #1 is at TDC on the compres-
d. Make sure that the timing chain tensioner rod sion stroke, align the “I” mark “a” on the gen-
comes out “d” of the timing chain tensioner erator rotor with the stationary pointer “b” on
housing smoothly. If there is rough move- the generator cover.
ment, replace the timing chain tensioner.
b
c
c. Install the timing chain onto both camshaft

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
sprockets, and then install the camshafts
EAS30269
onto the cylinder head.
INSTALLING THE CAMSHAFTS TIP
1. Install: • Lubricate the camshaft journal with the molyb-
• Exhaust camshaft “1” denum disulfide oil.
• Intake camshaft “2” • When installing the timing chain, start with the
exhaust camshaft and be sure to keep the tim-
ing chain as tight as possible on the exhaust
side.
• The camshafts should be installed onto the cyl-
inder head so that the alignment marks “c” on
the intake camshaft sprocket and the align-
ment marks “d” on the exhaust camshaft
sprocket align with the cylinder head mating
5-12
CAMSHAFTS
surface, as shown in the illustration. • When tightening the camshaft cap, tighten the
ECA13740 four bolts on the both ends of the cap tempo-
NOTICE rarily to lower the entire cap, while paying at-
Do not turn the crankshaft when installing tention not to twist the dowel pins and camshaft
the camshaft(s) to avoid damage or improper journal. After the camshaft cap touches the cyl-
valve timing. inder head, tighten the two bolts in the middle
to the specified torque and then the remaining
four bolts to the specified torque.
• To prevent the camshaft cap from cracking,
tighten the camshaft cap carefully by tapping
the camshaft using a soft-face hammer (both
for temporary and final tightening).
4. Install:
• Timing chain tensioner gasket New
• Timing chain tensioner
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a. Push the timing chain tensioner rod “1” into

the timing chain tensioner housing by hand.
2. Install:
TIP
• Dowel pins
While pushing the timing chain tensioner rod “a”,
• Exhaust camshaft cap “1”
turn it clockwise “b” with the timing chain ten-
• Intake camshaft cap “2”
sioner body “2” until if stops.
TIP
Make sure each camshaft cap is installed in its
original place. Refer to the identification marks
as follows:
“IN”: Intake
“EX”: Exhaust
b
2
a
2 1
IN
b. Lock the timing chain tensioner rod by setting
the circlip “3” into groove “4” while pushing
1 the timing chain tensioner rod.
EX
3
3. Install:
• Camshaft cap bolts
Camshaft cap bolt 4
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
ECA13730
NOTICE
The camshaft cap bolts must be tightened c. Install the timing chain tensioner to the cylin-
evenly or damage to the cylinder head, cam- der block.
shaft caps, and camshafts will result. TIP
Always use a new gasket.
TIP
• Lubricate the camshaft cap bolt seats with the
engine oil.
5-13
CAMSHAFTS
Timing chain tensioner bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
d. Release the timing chain tensioner rod by

pushing up the timing chain guide “5” from the
hole “6”.
TIP
Do not push up the timing chain.
Push up the timing chain guide “5” in the direc-
tion “c” shown.
7. Measure:
• Valve clearance
5 c Out of specification  Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-5.
8. Install:
• Timing chain guide (upper side)
6 • Gaskets New
(to the cylinder head cover)
TIP
Apply Yamaha bond No. 1215 “1” onto the mat-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ing surfaces of the cylinder head cover and gas-
kets.
5. Turn:
• Crankshaft
(several turns clockwise) 90890-85505
6. Check: (Three bond No.1215®)
• “I” mark “a”
Make sure that the “I” mark is aligned with the
stationary pointer “b” on the generator cover.
• Camshaft sprocket alignment marks “c” and
“d”
Make sure that the camshaft sprocket align-
ment marks are aligned with the cylinder
head mating surface.
Out of alignment  Correct.
Refer to the installation steps above.
b 9. Install:
• Cylinder head cover gasket New
• Cylinder head cover
Cylinder head cover bolt
a 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
Tighten the cylinder head cover bolts in stages
and in a crisscross pattern.
5-14
CYLINDER HEAD
EAS20044
CYLINDER HEAD
Removing the cylinder head
15 N・m (1.5 kgf・m, 11 lb・ft)
2
6
3
5
4
10 N・m (1.0 kgf・m, 7.4 lb・ft)
1st 10 N・m (1.0 kgf・m, 7.4 lb・ft)

2nd 20 N・m (2.0 kgf・m, 15 lb・ft)
3rd Specified angle 120˚

Camshafts Refer to “CAMSHAFTS” on page 5-7.
Exhaust assembly Refer to “ENGINE REMOVAL” on page 5-2.
Thermostat Refer to “THERMOSTAT” on page 6-7.
1 Coolant temperature sensor coupler 1 Disconnect.
2 Coolant temperature sensor 1
3 Gasket 1
4 Cylinder head 1
5 Cylinder head gasket 1
6 Dowel pin 2
5-15
CYLINDER HEAD
EAS30276
REMOVING THE CYLINDER HEAD

1. Remove:
• Cylinder head bolts
• Cylinder head nuts
TIP
• Loosen the bolts and nuts in the proper se-
quence as shown.
• Loosen each nut 1/2 of a turn at a time. After all
of the nuts are fully loosened, remove them.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
4 3
a. Place a straightedge “1” and a thickness
gauge “2” across the cylinder head.
Thickness gauge
8 7
90890-03180
Feeler gauge set
YU-26900-9
6 5
2 1
EAS30277
CHECKING THE CYLINDER HEAD

1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
TIP
Do not use a sharp instrument to avoid damag-
ing or scratching:
• Spark plug bore threads b. Measure the warpage.
• Valve seats c. If the limit is exceeded, resurface the cylinder
head as follows.
d. Place a 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder head
using a figure-eight sanding pattern.
TIP
To ensure an even surface, rotate the cylinder
head several times.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30282
INSTALLING THE CYLINDER HEAD

2. Check: 1. Install:
• Cylinder head • Dowel pins
Damage/scratches  Replace. • Cylinder head gasket New
• Cylinder head water jacket 2. Install:
Mineral deposits/rust  Eliminate. • Cylinder head
3. Measure: • Washers New
• Cylinder head warpage • Cylinder head nuts New
Out of specification  Resurface the cylinder • Cylinder head bolts
head. TIP
• Pass the timing chain through the timing chain
Warpage limit
cavity.
0.03 mm (0.0012 in)
5-16
CYLINDER HEAD
• Lubricate the cylinder head nuts and washers

with engine oil.
3. Tighten:
• Cylinder head nuts “1”–“6”
• Cylinder head bolts “7”, “8”
• Cylinder bolt “9”
Cylinder head nut
1st: 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
2nd: 20 N·m (2.0 kgf·m, 15 lb·ft)

R.
3rd: 120
Cylinder head bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
Cylinder bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
TIP
• Using the indicated tightening sequence, tight-
en the cylinder head nuts, cylinder head bolts,
and cylinder bolt when the cylinder head and
cylinder are cold.
• Use three steps to tighten the cylinder head
nuts.
5 6
1 2
9
3 4
7 8
4. Install:
• Exhaust camshaft
• Intake camshaft
Refer to “INSTALLING THE CAMSHAFTS”
on page 5-12.
5-17
VALVES AND VALVE SPRINGS
EAS20045

Removing the valves and valve springs
E
S
M

Cylinder head Refer to “CYLINDER HEAD” on page 5-15.
1 Valve lifter 8
2 Valve pad 8
3 Valve cotter 16
4 Valve spring retainer 8
5 Valve spring 8
6 Intake valve 4
7 Exhaust valve 4
8 Valve stem seal 8
9 Valve spring seat 8
10 Valve guide 8
5-18
EAS30283
TIP
REMOVING THE VALVES Remove the valve cotters by compressing the
The following procedure applies to all of the valve spring with the valve spring compressor
valves and related components. “1” and the valve spring compressor attachment
TIP “2”.
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal. 90890-04019
1. Remove: Valve spring compressor
• Valve lifter “1” YM-04019
• Valve pad “2” Valve spring compressor attach-
ment
TIP
90890-04114
Make a note of the position of each valve lifter
Valve spring compressor adapter
and valve pad so that they can be reinstalled in 19.5 mm
their original place. YM-04114
2. Check:
• Valve sealing 4. Remove:
Leakage at the valve seat  Check the valve • Valve spring retainer “1”
face, valve seat, and valve seat width. • Valve spring “2”
Refer to “CHECKING THE VALVE SEATS” • Valve “3”
on page 5-21. • Valve stem seal “4”
• Valve spring seat “5”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pour a clean solvent “a” into the intake and TIP
exhaust ports. Identify the position of each part very carefully so
b. Check that the valves properly seal. that it can be reinstalled in its original place.
TIP
There should be no leakage at the valve seat “1”.
EAS30284
CHECKING THE VALVES AND VALVE

GUIDES
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Remove: valves and valve guides.
• Valve cotters 1. Measure:
• Valve-stem-to-valve-guide clearance
5-19
Out of specification  Replace the valve

guide.
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” -
Valve stem diameter “b”
Valve-stem-to-valve-guide clear-
ance (intake)
0.010–0.037 mm (0.0004–0.0015
in)
Limit b. Install the new valve guide with the valve
0.080 mm (0.0032 in) guide installer “2” and valve guide remover
Valve-stem-to-valve-guide clear- “1”.
ance (exhaust)
0.025–0.052 mm (0.0010–0.0020 Valve guide position (intake)
in) 12.2–12.6 mm (0.48–0.50 in)
Limit Valve guide position (exhaust)
0.100 mm (0.0039 in) 12.2–12.6 mm (0.48–0.50 in)
a. Valve guide position

c. After installing the valve guide, bore the valve
guide with the valve guide reamer “3” to ob-
tain the proper valve-stem-to-valve-guide
clearance.
2. Replace:
• Valve guide
TIP
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 C (212 F) in an oven.
TIP
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ After replacing the valve guide, reface the valve
a. Remove the valve guide with the valve guide seat.
remover “1”.
5-20
2. Check:
Valve guide remover (ø4) • Valve seat
90890-04111
Pitting/wear  Replace the cylinder head.
Valve guide remover (4.0 mm)
YM-04111 3. Measure:
Valve guide installer (ø4) • Valve seat width “a”
90890-04112 Out of specification  Replace the cylinder
Valve guide installer (4.0 mm) head.
YM-04112
Valve guide reamer (ø4) Valve seat contact width (intake)
90890-04113 0.90–1.10 mm (0.0354–0.0433 in)
Valve guide reamer (4.0 mm) Limit
YM-04113 1.6 mm (0.06 in)
Valve seat contact width (ex-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
haust)
0.90–1.10 mm (0.0354–0.0433 in)
3. Eliminate: Limit
• Carbon deposits 1.6 mm (0.06 in)
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear  Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem  Replace the valve.
5. Measure:
• Valve stem runout
Out of specification  Replace the valve.
TIP
• When installing a new valve, always replace ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
the valve guide. a. Apply blue layout fluid “b” onto the valve face.
• If the valve is removed or replaced, always re-
place the valve stem seal.
Valve stem runout

0.040 mm (0.0016 in)
b. Install the valve into the cylinder head.

c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
TIP
EAS30285
Where the valve seat and valve face contacted
CHECKING THE VALVE SEATS one another, the blue layout fluid will have been
The following procedure applies to all of the removed.
valves and valve seats.
1. Eliminate: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Carbon deposits 4. Lap:
(from the valve face and valve seat) • Valve face
• Valve seat
5-21
TIP e. Apply a fine lapping compound to the valve

After replacing the cylinder head or replacing the face and repeat the above steps.
valve and valve guide, the valve seat and valve f. After every lapping procedure, be sure to
face should be lapped. clean off all of the lapping compound from the
valve face and valve seat.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
g. Apply blue layout fluid “b” onto the valve face.
a. Apply a coarse lapping compound “a” to the
valve face.
ECA13790
NOTICE
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
h. Install the valve into the cylinder head.

i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width “c” again. If the
valve seat width is out of specification, reface
and lap the valve seat.
b. Apply molybdenum disulfide oil onto the
valve stem.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Install the valve into the cylinder head. EAS30286
d. Turn the valve until the valve face and valve CHECKING THE VALVE SPRINGS
seat are evenly polished, then clean off all of The following procedure applies to all of the
the lapping compound. valve springs.
TIP 1. Measure:
For the best lapping results, lightly tap the valve • Valve spring free length “a”
seat while rotating the valve back and forth be- Out of specification  Replace the valve
tween your hands. spring.
Free length (intake)
36.73 mm (1.45 in)
Limit
34.89 mm (1.37 in)
Free length (exhaust)
36.73 mm (1.45 in)
Limit
34.89 mm (1.37 in)
5-22
(with an oil stone)
2. Measure:
• Valve spring tilt “a” 2. Lubricate:
Out of specification  Replace the valve • Valve stem “1”
spring. • Valve stem seal “2”
Spring tilt (intake)
1.6 mm (0.06 in) Recommended lubricant
Spring tilt (exhaust) Molybdenum disulfide oil
1.6 mm (0.06 in)
3. Install:
EAS30287
• Valve spring seat “1”
CHECKING THE VALVE LIFTERS • Valve stem seal “2” New
The following procedure applies to all of the • Valve “3”
valve lifters. • Valve spring “4”
1. Check: • Valve spring retainer “5”
• Valve lifter (into the cylinder head)
Damage/scratches  Replace the valve lift-
TIP
ers and cylinder head. • Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
facing up.
EAS30288
INSTALLING THE VALVES

valves and related components.
1. Deburr:
• Valve stem end
5-23
b. Smaller pitch 6. Lubricate:

• Valve pad
4. Install:
• Valve cotters
TIP Recommended lubricant
Install the valve cotters by compressing the Molybdenum disulfide oil
valve spring with the valve spring compressor
“1” and the valve spring compressor attachment 7. Lubricate:
“2”. • Valve lifter
Valve spring compressor Recommended lubricant
90890-04019 Engine oil
YM-04019 8. Install:
Valve spring compressor attach- • Valve pad
ment
• Valve lifter
90890-04114 ECA22150
Valve spring compressor adapter NOTICE
19.5 mm
YM-04114 After making sure that the valve pads are ful-
ly inserted, install the valve lifter taking care
so that the pads do not fall.
TIP
• The valve lifter must move smoothly when ro-
tated with a finger.
• Each valve lifter and valve pad must be rein-
stalled in its original position.
5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800
NOTICE
Hitting the valve tip with excessive force
could damage the valve.
5-24
CYLINDER AND PISTONS
EAS20046

Removing the cylinder and pistons
4
5
5
1 2
7
6
8 6
11
10 N・m (1.0 kgf・m, 7.4 lb・ft) 10
9

1 Coolant hose 1 Disconnect.
2 Timing chain guide (exhaust side) 1
3 Cylinder 1
4 Cylinder gasket 1
5 Dowel pin 2
6 Piston pin clip 4
7 Piston pin 2
8 Piston 2
9 Top ring 2
10 2nd ring 2
11 Oil ring 2
5-25
EAS30289
• Oil ring
REMOVING THE PISTON
TIP
The following procedure applies to all of the pis- When removing a piston ring, open the end gap
ton. with your fingers and lift the other side of the ring
1. Remove: over the piston crown.
• Piston pin clips “1”
• Piston pin “2”
• Piston “3”
ECA13810
NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
• Before removing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crank-
case. EAS30291
CHECKING THE CYLINDERS AND PISTONS

• For reference during installation, put an identi-
The following procedure applies to all of the cyl-
fication mark on each piston crown.
inders and pistons.
• Before removing the piston pin, deburr the pis-
1. Check:
ton pin clip’s groove and the piston’s pin bore
• Piston wall
area. If both areas are deburred and the piston
• Cylinder wall
pin is still difficult to remove, remove it with the
Vertical scratches  Replace the cylinder,
piston pin puller set “4”.
piston and piston rings as a set.
2. Measure:
Piston pin puller set • Piston-to-cylinder clearance
90890-01304
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Piston pin puller
YU-01304 a. Measure cylinder bore with the cylinder bore
gauge.
TIP
Measure cylinder bore by taking side-to-side
and front-to-back measurements of the cylinder.
Bore
68.000–68.010 mm (2.6772–
2.6776 in)
Wear limit
68.060 mm (2.6795 in)
Bore = maximum of D1, D2, D3, D4, D5, D6
2. Remove:
• Top ring
• 2nd ring b. If out of specification, replace the cylinder,
piston and piston rings as a set.
5-26
c. Measure piston skirt diameter “a” with the mi-

crometer. Piston ring
Top ring
Ring side clearance
0.030–0.065 mm (0.0012–0.0026
in)
Side clearance limit
b 0.115 mm (0.0045 in)
a
2nd ring
Ring side clearance
0.020–0.055 mm (0.0008–0.0022
in)
Side clearance limit
0.115 mm (0.0045 in)
b. 9.0 mm (0.35 in) from the bottom edge of the
piston
Piston
Diameter
67.975–67.990 mm (2.6762–
2.6768 in)
d. If out of specification, replace the piston and

piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
2. Install:
Piston-to-cylinder clearance = • Piston ring
Cylinder bore - (into the cylinder)
Piston skirt diameter
TIP
Use the piston crown to level the piston ring near
Piston-to-cylinder clearance the bottom of the cylinder where the cylinder
0.010–0.035 mm (0.0004–0.0014 wear is lowest.
in)
3. Measure:
f. If out of specification, replace the cylinder, • Piston ring end gap
piston and piston rings as a set. Out of specification  Replace the piston ring
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ set.
TIP
EAS30292
The oil ring expander spacer’s end gap cannot
CHECKING THE PISTON RINGS be measured. If the oil ring rail’s gap is exces-
1. Measure: sive, replace all three piston rings.
• Piston ring side clearance
Out of specification  Replace the piston
Piston ring
and piston rings as a set.
Top ring
TIP End gap limit
Before measuring the piston ring side clearance, 0.60 mm (0.0236 in)
eliminate any carbon deposits from the piston 2nd ring
ring grooves and piston rings. End gap limit
0.85 mm (0.0335 in)
5-27
b
a. Bottom of cylinder 4. Calculate:
b. Upper of cylinder • Piston-pin-to-piston-pin-bore clearance
Out of specification  Replace the piston pin
EAS30293
CHECKING THE PISTON PINS and piston as a set.

The following procedure applies to both of the Piston-pin-to-piston-pin-bore clearance =
piston pins. Piston pin bore inside diameter -
Piston pin outside diameter
1. Check:
• Piston pin
Blue discoloration/grooves  Replace the Piston-pin-to-piston-pin-bore
piston pin and then check the lubrication sys- clearance
tem. 0.002–0.018 mm (0.0001–0.0007
2. Measure: in)
• Piston pin outside diameter “a” EAS30294
Out of specification  Replace the piston pin. INSTALLING THE PISTON AND CYLINDER
Piston pin outside diameter The following procedure applies to all of the pis-
15.995–16.000 mm (0.6297– tons and cylinders.
0.6299 in) 1. Install:
Limit • Oil ring expander “1”
15.975 mm (0.6289 in) • Lower oil ring rail “2”
• Upper oil ring rail “3”
• 2nd ring “4”
• Top ring “5”
(into the piston)
TIP
Be sure to install the top and 2nd rings so that
the manufacturer marks or numbers “a” face up.
3. Measure:
• Piston pin bore inside diameter “b”
Out of specification  Replace the piston.
Piston pin bore inside diameter
16.002–16.013 mm (0.6300–
0.6304 in)
Limit 2. Install:
16.043 mm (0.6316 in) • Piston “1”
• Piston pin “2”
• Piston pin clips “3” New
TIP
• Apply engine oil onto the piston pin.
5-28
• Make sure the mark “a” on the piston points to-

wards the exhaust side of the cylinder.
• Reinstall each piston into its original cylinder.
• Before installing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crank-
case.
• Make sure that the clip ends “b” are positioned
away from the cutout “c” in the piston as shown
in the illustration.
a. Top ring
b. 2nd ring
c. Upper oil ring rail
d. Oil ring expander
e. Lower oil ring rail
A. Exhaust side
6. Install:
a • Cylinder
• Cylinder bolt
TIP
• While compressing the piston rings, install the
1 cylinder.
3 b • Pass the timing chain and timing chain guide
(intake side) through the timing chain cavity.
7. Tighten:
• Cylinder bolt
Cylinder bolt
2 3 2 c
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
3. Install:
• Dowel pins
• Cylinder gasket New
4. Lubricate:
• Piston
• Piston rings
• Cylinder
Engine oil
5. Offset:
• Piston ring end gaps
5-29
ELECTRIC STARTER
EAS20052
ELECTRIC STARTER
Removing the starter motor
10 N・m (1.0 kgf・m, 7.4 lb・ft)
1
7 N・m (0.7 kgf・m, 5.2 lb・ft)
FW
D

cowling 4-1.
1 Starter motor lead 1 Disconnect.
2 Starter motor assembly 1
5-30
ELECTRIC STARTER
Disassembling the starter motor
5 N・m (0.5 kgf・m, 3.7 lb・ft) 11 N・m (1.1 kgf・m, 8.1 lb・ft)
* When replacing any of the starter motor front cover, armature assembly, starter motor yoke, insulator, and
starter motor rear cover, replace the starter motor assembly.
1 Starter motor front cover 1
2 Armature assembly 1
3 Starter motor yoke 1
4 O-ring 2
5 Brush holder set 1
6 Insulator 1
7 Starter motor rear cover 1
5-31
ELECTRIC STARTER
EAS30325
CHECKING THE STARTER MOTOR

1. Check:
• Commutator
Dirt  Clean with 600 grit sandpaper.
2. Measure:
• Mica undercut “a”
Out of specification  Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commutator.
Mica undercut (depth) 1. Commutator resistance
0.70 mm (0.03 in) 2. Insulation resistance
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP
The mica of the commutator must be undercut to 4. Measure:
ensure proper operation of the commutator. • Brush length “a”
Out of specification  Replace the brush
holder set.
Brush overall length
12.0 mm (0.47 in)
Limit
6.50 mm (0.26 in)
3. Measure:
• Armature assembly resistances (commutator
and insulation)
Out of specification  Replace the starter
motor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resistances
with the digital circuit tester. 5. Measure:
• Brush spring force
Digital circuit tester (CD732) Out of specification  Replace the brush
90890-03243 holder set.
eter Brush spring force
YU-A1927 6.02–6.51 N (614–664 gf, 21.69–
23.45 oz)
Armature coil resistance
0.0105–0.0195 
Insulation resistance
No continuity (Above 1 M)
b. If any resistance is out of specification, re-

place the starter motor assembly.
5-32
ELECTRIC STARTER
6. Check: TIP
• Gear teeth Connect the starter motor lead to the starter mo-
Damage/wear  Replace the starter motor tor in the direction shown in the illustration.
assembly.
7. Check: 1
• Bearing
Damage/pitting  Replace the starter motor
assembly.
EAS30326
ASSEMBLING THE STARTER MOTOR

1. Install:
• Insulator “1”
TIP 2
Install the insulator so that the slot “a” is posi-
tioned as shown in the illustration.
2. Install:
• Starter motor yoke “1”
• Starter motor rear cover “2”
• Starter motor front cover “3”
TIP
• Align the match mark “a” on the starter motor
rear cover with the match mark “b” on the start-
er motor yoke.
• Align the match mark “c” on the starter motor
yoke with the match mark “d” on the starter mo-
tor front cover.
2 1 3
a b c d
EAS30327
INSTALLING THE STARTER MOTOR

1. Install:
• Starter motor “1”
• Starter motor lead “2”
5-33
V-BELT AUTOMATIC TRANSMISSION
EAS20050

Removing the V-belt case cover
7 N・m (0.7 kgf・m, 5.2 lb・ft)
(3)
11
(2) 5
S 4
3
12
S 13
(4)
9
10 LT
11 N・m (1.1 kgf・m, 8.1 lb・ft)

8
(6) 7
6
10 N・m (1.0 kgf・m, 7.4 lb・ft) (3)

2
24 N・m (2.4 kgf・m, 18 lb・ft) 1
FW
S D
7 N・m (0.7 kgf・m, 5.2 lb・ft)

cowling 4-1.
cover (right)/Footboard (right) 4-11.
1 Crankshaft end access cover 1
2 Damper 1
3 V-belt case air filter case cover 1
4 O2 sensor lead 1
5 V-belt case air filter case 1
6 V-belt case air filter element (right) 1
7 Outer V-belt case 1
8 Outer V-belt case gasket 1
9 Bearing retainer 1
10 Bearing 1
11 Circlip 1
12 Oil seal 1
13 Bearing 1
5-34
Removing the V-belt and primary/secondary sheave
10
3.0 N・m (0.30 kgf・m, 2.2 lb・ft)
13
15
10 N・m (1.0 kgf・m, 7.4 lb・ft)
18 N・m (1.8 kgf・m, 13 lb・ft)
11
14 13
(3) 12
8
5 7
24 N・m (2.4 kgf・m, 18 lb・ft)

4
90 N・m (9.0 kgf・m, 66 lb・ft) FW
D
160 N・m (16 kgf・m, 118 lb・ft)
1 3 2
*1 Apply YAMAHA GREASE “G” (Shell Sunlight Grease 3®).
*2 Apply YAMAHA GREASE “H” (Polyurea Grease®).
1 Primary sheave nut 1
2 Spacer 1
3 O-ring 2
4 Primary sheave assembly 1
5 Secondary sheave nut 1
6 Secondary sheave assembly 1
7 V-belt 1
8 Primary fixed sheave 1
9 V-belt case air duct joint clamp 1 Loosen.
10 V-belt case air duct 1
11 Inner V-belt case plate 1
12 Inner V-belt case 1
13 Dowel pin 2
14 Plate 1
15 Inner V-belt case seal 1
5-35
Disassembling the primary sheave
FW
D
*1 Apply YAMAHA GREASE “H” (Polyurea Grease®).

*2 When replacing the primary sliding sheave or collar, replace them as a set.
1 Cam 1
2 Slider 8
3 Primary sheave weight 8
4 Primary sliding sheave 1
5 Collar 1
6 Oil seal 2
5-36
Disassembling the secondary sheave
FW
D 9
5
6 8
90 N・m (9.0 kgf・m, 66 lb・ft)
* Apply YAMAHA GREASE “H” (Polyurea Grease®).

1 Secondary sheave spring seat nut 1
2 Upper spring seat 1
3 Secondary sheave compression spring 1
4 Spring seat 1
5 Guide pin 6
6 Secondary sliding sheave 1
7 O-ring 2
8 Oil seal 2
9 Secondary fixed sheave 1
5-37
EAS31435 EAS30312
REMOVING THE PRIMARY SHEAVE AND DISASSEMBLY THE SECONDARY SHEAVE

SECONDARY SHEAVE 1. Loosen:
1. Remove: • Secondary sheave spring seat nut “1”
• Primary sheave nut “1” TIP
• Secondary sheave nut “2” • While holding the secondary fixed sheave “2”
TIP with the sheave holder “3”, loosen the second-
While holding the primary and secondary ary sheave spring seat nut with the locknut
sheave with the sheave holder “3”, loosen the wrench “4”.
nut. • Do not loosen the secondary sheave spring
seat nut “1” more than 1/4 turn.
Sheave holder
90890-01481 Sheave holder
90890-01481
Locknut wrench
90890-01348
Locknut wrench
YM-01348
3
1 4
3 4
3
1
2
2. Remove:
• Secondary sheave spring seat nut “1”
TIP
2 Install the sheave spring compressor “2” and
3 sheave fixed block “3” onto the secondary
sheave assembly as shown. Then, compress
2. Remove: the spring, and remove the secondary sheave
• Primary sheave assembly “1” spring seat nut with locknut wrench “4”.
• Secondary sheave assembly “2”
• V-belt “3” Sheave spring compressor
TIP 90890-04134
• Before removal, put alignment marks “a” and Sheave spring compressor
“b” as shown. YM-04134
Locknut wrench
• Align these marks during reassembly.
90890-01348
Locknut wrench
3 YM-01348
2 Sheave fixed block
90890-04135
Sheave fixed bracket
a YM-04135
b 1
5-38
EAS30317
CHECKING THE PRIMARY SHEAVE

WEIGHTS
The following procedure applies to all of the pri-
mary sheave weights.
1. Check:
• Primary sheave weight
Cracks/damage/wear  Replace.
2. Measure:
EAS30315
• Primary sheave weight outside diameter
CHECKING THE V-BELT Out of specification  Replace.
1. Check:
• V-belt “1” Weight outside diameter
Cracks/damage/wear  Replace. 25.0 mm (0.98 in)
Grease/oil  Clean the primary and second- Limit
ary sheave. 24.5 mm (0.96 in)
2. Measure:
• V-belt width “a”
Out of specification  Replace.
TIP
Measure the V-belt width as illustration.
V-belt
V-belt width
32.9 mm (1.30 in)
Limit
31.4 mm (1.24 in)
EAS30318
CHECKING THE SLIDERS

a 2 1 The following procedure applies to all of the slid-
ers.
1. Check:
• Slider
3
EAS30319
CHECKING THE SECONDARY SHEAVE

1. Check:
• Secondary fixed sheave
2. Plastic board • Secondary sliding sheave
3. Ruler Cracks/damage/wear  Replace the sec-
EAS30316
ondary fixed and sliding sheaves as a set.
CHECKING THE PRIMARY SHEAVE 2. Check:
1. Check: • Torque cam groove “1”
• Primary sliding sheave Damage/wear  Replace the secondary
• Primary fixed sheave fixed and sliding sheaves as a set.
Cracks/damage/wear  Replace the primary 3. Check:
sliding sheave and primary fixed sheave as a • Guide pin “2”
set. Damage/wear  Replace the secondary
fixed and sliding sheaves as a set.
EAS31436
CHECKING THE V-BELT CASE AIR DUCT

1. Check:
• V-belt case air duct
5-39
EAS30320 2. Install:
ASSEMBLING THE PRIMARY SHEAVE • Guide pins
1. Clean: TIP
• Primary fixed sheave Before installing the guide pin, align the position
• Primary sliding sheave (where fixed sheave rivet head “a” and guide pin
• Collar hole “b” are in alignment with each other) with
• Cam alignment mark “c” of the sliding sheave. Install
• Primary sheave weights the guide pin. Then, make sure that the sliding
2. Install: sheave slides to the LOW side without an inter-
• Primary sheave weights “1” ference of rivet head “d”.
• Sliders “2”
• Cam “3”
TIP
Do not apply the grease inside of the primary
sheave.
EAS30321
ASSEMBLING THE SECONDARY SHEAVE

1. Lubricate:
• Secondary fixed sheave inner surface “1”
• Secondary sliding sheave inner surface “2”
• Oil seals New 3. Lubricate:
(with the recommended lubricant) • Guide pin groove “1”
Recommended lubricant • O-rings “2” New
YAMAHA GREASE “H” (Poly- (with the recommended lubricant)
urea Grease®)
YAMAHA GREASE “H” (Poly-
urea Grease®)
5-40
TIP
While holding the secondary fixed sheave “2”
with the sheave holder “3”, tighten the second-
ary sheave spring seat nut “1” with the locknut
wrench “4”.
Sheave holder
90890-01481
Locknut wrench
90890-01348
4. Install: Locknut wrench
• Secondary sheave spring seat nut “1” YM-01348
TIP
• Install the secondary sheave spring seat nut Secondary sheave spring seat
with its beveled side “a” facing the spring seat. nut
T.
• Attach the sheave spring compressor “2” and 90 N·m (9.0 kgf·m, 66 lb·ft)
R.
sheave fixed block “3” onto the secondary
sheave as shown.
Then compress the spring, and temporarily 3
tighten the secondary sheave spring seat nut. 4
4
90890-04134 3
YM-04134 1
Sheave fixed block 2
90890-04135
Sheave fixed bracket EAS31437
YM-04135 INSTALLING THE PRIMARY SHEAVE
ASSEMBLY, SECONDARY SHEAVE
ASSEMBLY AND V-BELT
1. Apply:
a
• Sealant
(onto the inner V-belt case seal)
90890-85505
1
2
2. Install:
5. Tighten: • V-belt case air duct joint clamp “1”
• Secondary sheave spring seat nut “1” • V-belt case air duct “2”
5-41
TIP
• Align the projection “a” in the V-belt case air Secondary sheave nut
90 N·m (9.0 kgf·m, 66 lb·ft)
duct “2” with the slot “b” on the V-belt case air
T.
R.
duct joint clamp “1”.
• Align the projection “c” in the V-belt case air Sheave holder
duct “2” with the slot “d” in the inner V-belt case 90890-01481
“3”.
2
c 3
d
1
a
1
b 2
2
5. Tighten:
3. Install: • Primary sheave nut “1”
• Primary fixed sheave “1” ECA22200
• V-belt “2” NOTICE

• Secondary sheave assembly “3” • Before tightening the nut to remount the
primary sheave, make sure that the serra-
ECA22160
NOTICE
tions of the cam are fitted firmly into the
Do not allow grease to contact the V-belt, pri- serrations of the crankshaft.
mary and secondary sheave. • Also, make sure that cam is properly seat-
TIP ed.
• When installing the belt, screw M6 (more than • Apply grease to the thread and seat of the
45 mm (1.77 in)) bolts “4” to spread apart the primary sheave nut.
secondary sheave and then install the V-belt.
Make sure to install the V-belt with the arrow Recommended lubricant
facing in the direction shown. YAMAHA GREASE “G” (Shell
• Install the V-belt and secondary sheave as- Sunlight Grease 3®)
sembly then pass the V-belt the primary
sheave side. TIP
• Align the “a” and “b” during reassembly. While holding the primary sheave with the
sheave holder “2”, tighten the primary sheave
nut.
3 1
a Primary sheave nut
160 N·m (16 kgf·m, 118 lb·ft)
T.
R.
2
Sheave holder
4 90890-01481
b
4
4. Tighten:
• Secondary sheave nut “1”
TIP
While holding the secondary sheave with the
sheave holder “2”, tighten the secondary sheave
nut.
5-42
a
1
2
1
EAS31235
INSTALLING THE V-BELT CASE

1. Install:
• Oil seal “1” New
(into outer V-belt case)
Installed depth of oil seal “a”
4.0–4.3 mm (0.16–0.17 in)
2. Fill the space “b” shown in the illustration with

10 g (0.35 oz) or more of lithium-soap-based
grease.
1
a
3. Install:
• Bearing retainer “1”
TIP
• Install the bearing retainer “1” with its mark “a”
facing outward.
• Apply locking agent (LOCTITE®) to the
threads of the bearing retainer screw.
V-belt case bearing retainer

screw
T.
11 N·m (1.1 kgf·m, 8.1 lb·ft)

R.
LOCTITE®
5-43
GENERATOR AND STARTER CLUTCH
EAS20140

Removing the generator rotor and starter clutch
2
3
4
1
E (17)
E
10 N・m (1.0 kgf・m, 7.4 lb・ft)
1st 65 N・m (6.5 kgf・m, 48 lb・ft)

LT (3) 2nd Specified angle 120˚
E
32 N・m (3.2 kgf・m, 24 lb・ft)

Drain.
page 3-28.
Drain.
page 3-31.
cowling 4-1.
cover (left)/Footboard (left) 4-11.
V-belt case air filter element (left)/Generator
cover protector/Water pump inlet pipe/Water Refer to “WATER PUMP” on page 6-9.
1 Centerstand lock solenoid coupler 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 Stator coil coupler 1 Disconnect.
4 Generator cover 1
5-44
Removing the generator rotor and starter clutch
5
E
8
7
12
13 14
E
15
11
E 10 6 (17)
E
10 N・m (1.0 kgf・m, 7.4 lb・ft)
9 1st 65 N・m (6.5 kgf・m, 48 lb・ft)

LT (3) 2nd Specified angle 120˚
E
32 N・m (3.2 kgf・m, 24 lb・ft)

5 Generator cover gasket 1
6 Dowel pin 2
7 Starter clutch idle gear shaft 1
8 Starter clutch idle gear 1
9 Generator rotor nut 1
10 Spacer 1
11 Generator rotor 1
12 Woodruff key 1
13 Washer 1
14 Starter clutch gear 1
15 Starter clutch 1
5-45
Removing the stator coil and oil tank
10 N・m (1.0 kgf・m, 7.4 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)

(7)
1
LT
10 3
(2)
(3) 5
E
LT
3 (3)
6
12 N・m (1.2 kgf・m, 8.9 lb・ft) 8

4
LT
9
E
* When replacing the crankshaft position sensor or stator coil, replace them as a set.
1 Oil tank 1
2 Oil tank gasket 1
3 Dowel pin 2
4 Oil strainer 1
5 Crankshaft position sensor 1
6 Stator coil 1
7 Bearing cover 1
8 Oil seal 1
9 Bearing 1
10 Bearing 1
5-46
EAS30867
REMOVING THE GENERATOR Flywheel puller

1. Remove: 90890-01362
• Generator cover Heavy duty puller
TIP YU-33270-B
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.
EAS30868
REMOVING THE STARTER CLUTCH

1. Remove:
• Starter clutch bolts “1”
2. Remove: • Starter clutch
• Generator rotor nut “1”
TIP
• Spacer “2” • While holding the generator rotor “2” with the
TIP sheave holder “3”, remove the starter clutch
• While holding the generator rotor “3” with the bolts.
sheave holder “4”, loosen the generator rotor • Do not allow the sheave holder to touch the
nut. projection on the generator rotor.
• Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701
Sheave holder Primary clutch holder
90890-01701 YS-01880-A
YS-01880-A
1
2
3 4 3
2
1 EAS30869
CHECKING THE STARTER CLUTCH

• Generator rotor “1” • Starter clutch rollers “1”
(with the flywheel puller “2”) Damage/wear  Replace.
• Woodruff key
TIP
Make sure the flywheel puller is centered over
the generator rotor.
5-47
EAS31439
CHECKING THE OIL STRAINER

1. Check:
• Oil strainer
Damage  Replace.
Contaminants  Clean with solvent.
EAS31440
ASSEMBLING THE OIL TANK

1 1. Install:
• Bearing
2. Check: TIP
• Starter clutch idle gear “1” Seal “a” is adhered only on one side of the bear-
• Starter clutch gear “2” ing. Note the press-in orientation.
Burrs/chips/roughness/wear  Replace the
defective part(s).
EAS30871
INSTALLING THE STARTER CLUTCH

3. Check: 1. Install:
• Starter clutch gear contacting surfaces • Starter clutch
Damage/pitting/wear  Replace the starter • Starter clutch bolts “1”
clutch gear.
4. Check: Starter clutch bolt
• Starter clutch operation 32 N·m (3.2 kgf·m, 24 lb·ft)
T.
LOCTITE®
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch gear “1” onto the
starter clutch “2” and hold the starter clutch. TIP
• While holding the generator rotor “2” with the
b. When turning the starter clutch gear counter-
sheave holder “3”, tighten the starter clutch
clockwise “A”, the starter clutch and the start-
bolts.
er clutch gear should engage, otherwise the
starter clutch is faulty and must be replaced.
c. When turning the starter clutch gear clock-
wise “B”, it should turn freely, otherwise the
starter clutch is faulty and must be replaced. Sheave holder
90890-01701
YS-01880-A
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-48
2 3
1
EAS30872
INSTALLING THE GENERATOR Generator rotor nut (2nd)

1. Install: Specified angle 120
T.
• Woodruff key
R.
• Generator rotor “1” TIP
• Spacer “2” • When tightening the generator rotor nut, be
• Generator rotor nut “3” New sure to use a beam type torque wrench.
TIP • Tighten the nut until it is at the specified angle.
• Clean the tapered portion of the crankshaft and
the generator rotor hub.
• When installing the generator rotor, make sure
the woodruff key is properly sealed in the key-
way of the crankshaft.
• Lubricate the generator rotor nut seats and
threads with engine oil.
3. Apply:
1 • Sealant
(onto the crankshaft position sensor/stator
lead grommet)
2 Yamaha bond No. 1215

3 90890-85505
2. Tighten:
• Generator rotor nut “1”
Generator rotor nut (1st)
65 N·m (6.5 kgf·m, 48 lb·ft)
T.
R.
TIP
• While holding the generator rotor “2” with the
sheave holder “3”, tighten the generator rotor
nut.
4. Install:
Sheave holder • Generator cover
90890-01701
Primary clutch holder Generator cover bolt
YS-01880-A 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
5-49
TIP
Tighten the generator cover bolts in stages and
in a crisscross pattern.
5-50
CLUTCH
EAS20055
CLUTCH
Removing the clutch
3 2
1
65 N・m (6.5 kgf・m, 48 lb・ft)

cowling 4-1.
Drain.
page 3-28.
Drain.
page 3-31.
Refer to “GENERATOR AND STARTER
Generator cover CLUTCH” on page 5-44.
1 Clutch assembly nut 1
2 Clutch assembly 1
3 Washer 1
5-51
CLUTCH
Disassembling the clutch

130 N・m (13 kgf・m, 96 lb・ft)
13
12
1
2
3
15 4
14 5
6 E
7
11 8
6
7
8
6
7 9
8 (6)
6
7
8
6
7
8
6
7
5
6
10

1 Clip 1
2 Spring stopper plate 1
3 Clutch spring plate 1
4 Pressure plate 1
5 Clutch plate 2 2
6 Clutch damper spring 7
7 Friction plate 6
8 Clutch plate 1 5
9 Clutch spring 6
10 Thrust plate 1
11 Clutch boss nut 1
12 Primary drive gear 1
13 Bearing 2
14 Clutch boss 1
15 Collar 1
5-52
CLUTCH
Disassembling the clutch
130 N・m (13 kgf・m, 96 lb・ft)
16
18
17
(12)

16 Thrust plate 1
17 Clutch weight 12
18 Clutch housing 1
5-53
CLUTCH
EAS30346
REMOVING THE CLUTCH

1. Remove:
• Clutch assembly nut “1”
• Clutch assembly “2”
TIP
• Before removal, put alignment marks “a” and
“b” as shown.
• While holding the clutch assembly with the ro-
tor holding tool “3”, loosen the clutch assembly
nut.
2. Remove:
• Align these marks during reassembly.
• Spring stopper plate “1”
TIP
Rotor holding tool To ensure proper balance of the clutch assem-
90890-01235
bly, one to three holes “a”, or no hole at all, may
Universal magneto and rotor
holder have been drilled in the spring stopper plate. Be-
YU-01235 fore removing the spring stopper plate, make
alignment marks on both the plate and the clutch
housing so that the plate can be reinstalled in its
1 original position.
a
3. Loosen:
3 • Clutch boss nut “1”
1 TIP
While holding the clutch boss “2” with the univer-
sal clutch holder “3”, loosen the clutch boss nut.
2 Universal clutch holder

90890-04086
EAS31441
YM-91042
DISASSEMBLING THE CLUTCH
1. Remove:
• Clip “1”
TIP 1
While compressing the clutch springs with the
clutch spring compressor “2”, remove the clip.
Clutch spring compressor 2

90890-01482
3
5-54
CLUTCH
EAS30348
CHECKING THE FRICTION PLATES Clutch plate 1 thickness

The following procedure applies to all of the fric- 1.30–1.50 mm (0.051–0.059 in)
tion plates. Warpage limit
1. Check: 0.10 mm (0.004 in)
• Friction plate Clutch plate 2 thickness
Damage/wear  Replace the friction plates 1.80–2.00 mm (0.071–0.079 in)
Warpage limit
as a set.
0.20 mm (0.008 in)
2. Measure:
• Friction plate thickness
Out of specification  Replace the friction
plates as a set.
TIP
Measure the friction plate at four places.
Friction plate thickness

2.92–3.08 mm (0.115–0.121 in)
Wear limit
2.82 mm (0.111 in)
EAS31442
CHECKING THE CLUTCH DAMPER

SPRINGS
clutch damper springs.
1. Check:
• Clutch damper spring
Damage  Replace.
2. Measure:
• Clutch damper spring free height “a”
Out of specification  Replace the clutch
EAS30349
CHECKING THE CLUTCH PLATES damper springs as a set.

The following procedure applies to all of the Clutch damper spring height
clutch plates. 3.50 mm (0.14 in)
1. Check: Minimum height
• Clutch plate 3.10 mm (0.12 in)
Damage  Replace the clutch plates as a
set.
2. Measure:
• Clutch plate warpage
(with a surface plate and thickness gauge “1”)
plates as a set.
Thickness gauge
90890-03180
a
Feeler gauge set
YU-26900-9
EAS30350
CHECKING THE CLUTCH SPRING PLATE

1. Check:
• Clutch spring plate
Damage  Replace.
2. Measure:
• Clutch spring plate free height “a”
5-55
CLUTCH
Out of specification  Replace the clutch ratic clutch operation.

spring plate.
Clutch spring plate height
4.70 mm (0.19 in)
Minimum height
4.40 mm (0.17 in)
EAS30353
CHECKING THE CLUTCH BOSS

1. Check:
• Clutch boss splines
a Damage/pitting/wear  Replace the clutch
boss.
EAS30351
TIP
CHECKING THE CLUTCH SPRINGS Pitting on the clutch boss splines will cause er-
The following procedure applies to all of the ratic clutch operation.
clutch springs.
1. Check:
• Clutch spring
Damage  Replace the clutch springs as a
set.
2. Measure:
• Clutch spring free length
springs as a set.
Clutch spring free length
31.90 mm (1.26 in) EAS31443
Limit CHECKING THE PRESSURE PLATE AND
24.80 mm (0.98 in) THRUST PLATE
1. Check:
• Pressure plate “1”
• Thrust plate “2”
EAS30352
CHECKING THE CLUTCH HOUSING

1. Check:
• Clutch housing dogs
Damage/pitting/wear  Deburr the clutch
EAS31444
ASSEMBLING THE CLUTCH

housing dogs or replace the clutch housing.
1. Install:
TIP • Clutch boss
Pitting on the clutch housing dogs will cause er- • Primary drive gear
5-56
CLUTCH
• Clutch boss nut

2. Tighten:
• Clutch boss nut “1”
Clutch boss nut
130 N·m (13 kgf·m, 96 lb·ft)
T.
R.
TIP
While holding the clutch boss “2” with the univer-
sal clutch holder “3”, tighten the clutch boss nut.

90890-04086
YM-91042
3. Install:
• Clutch weights
• Thrust plate “1”
• Clutch springs
• Clutch damper springs “2”
• Clutch plates 2 “3”
• Friction plates “4” 4. Install:
• Clutch plates 1 “5” • Clip “1”
• Pressure plate “6” TIP
• Clutch spring plate “7” While compressing the clutch springs with the
TIP clutch spring compressor “2”, install the clip.
• Clutch damper spring “a” installed at the end
must be installed backwards. Clutch spring compressor
• The pressure plate “6” and thrust plate “1” can 90890-01482
be identified by punch mark “b” on the pressure
plate.
5-57
CLUTCH
EAS30363
INSTALLING THE CLUTCH

1. Install:
• Clutch assembly “1”
• Clutch assembly nut “2”
Clutch assembly nut
65 N·m (6.5 kgf·m, 48 lb·ft)
T.
R.
TIP
• Align the “a” and “b” during reassembly.
• While holding the clutch assembly with the ro-
tor holding tool “3”, tighten the clutch assembly
nut.
Rotor holding tool

90890-01235
Universal magneto and rotor
holder
YU-01235
a
2
b
1
3
2
5-58
OIL PUMP
EAS20054
OIL PUMP
Removing the oil pump assembly
4
LT
10 N・m (1.0 kgf・m, 7.4 lb・ft)
6
3
2
(3)
5
10 N・m (1.0 kgf・m, 7.4 lb・ft)

cowling 4-1.
gear CLUTCH” on page 5-44.
1 Oil pump assembly 1
2 Oil pump drive chain 1
3 Gasket 2
4 Oil delivery pipe 1
5 Oil pipe 1
6 Relief valve assembly 1
5-59
OIL PUMP
Disassembling the oil pump assembly
6 N・m (0.6 kgf・m, 4.4 lb・ft)
7
6
9
8
12 10
11 E
2
E
E
6 N・m (0.6 kgf・m, 4.4 lb・ft)
4
3 FW
D
5
* When replacing any of the part, replace the oil pump assembly.
1 Oil pump housing 1 1
2 Dowel pin 2
3 Oil pump outer rotor 1 1
4 Oil pump inner rotor 1 1
5 Pin 1
6 Washer 1
7 Oil pump housing center 1
8 Oil pump outer rotor 2 1
9 Oil pump inner rotor 2 1
10 Pin 1
11 Oil pump driven gear 1
12 Oil pump housing 2 1
5-60
OIL PUMP
EAS30337
CHECKING THE OIL PUMP

1. Check:
• Oil pump driven gear “1”
Cracks/damage/wear  Replace the oil
pump assembly.
EAS30342
ASSEMBLING THE OIL PUMP

1. Lubricate:
• Inner rotor
• Outer rotor
• Oil pump shaft
2. Check: Recommended lubricant

• Oil pump operation Engine oil
Rough movement  Repeat steps (1) and
(2) or replace the oil pump assembly. 2. Install:
• Inner rotors
TIP
When installing the inner rotor, align the pins “1”
in the oil pump shaft with the grooves “a” in the
inner rotor.
EAS30338
CHECKING THE RELIEF VALVE

1
1. Check: a
• Relief valve body a
EAS30742 3. Check:
CHECKING THE OIL PIPES • Oil pump operation
1. Check: Refer to “CHECKING THE OIL PUMP” on
• Oil pipe page 5-61.
• Oil delivery pipe EAS30343
Damage  Replace. INSTALLING THE OIL PUMP
Obstruction  Wash and blow out with com- 1. Install:
pressed air. • Oil pump assembly
EAS30785
CHECKING THE OIL PUMP DRIVE CHAIN Oil pump bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
1. Check:
T.
R.
• Oil pump drive chain ECA13890
Cracks/stiffness  Replace the oil pump NOTICE

chain and oil pump assembly as a set. After tightening the bolts, make sure the oil
pump turns smoothly.
5-61
CRANKCASE
EAS20059
CRANKCASE
Separating the crankcase
7 4
10 N・m (1.0 kgf・m, 7.4 lb・ft)

(6) (8)
3
(5)
5
10 N・m (1.0 kgf・m, 7.4 lb・ft)

2 LT
(6)
LT
LT
(2) (4)
8
(4)
6
24 N・m (2.4 kgf・m, 18 lb・ft)
9
7 N・m (0.7 kgf・m, 5.2 lb・ft)

43 N・m (4.3 kgf・m, 32 lb・ft)
55 N・m (5.5 kgf・m, 41 lb・ft) 1

Engine Refer to “ENGINE REMOVAL” on page 5-2.
Refer to “CYLINDER AND PISTONS” on
Cylinder/Pistons page 5-25.
Oil cooler Refer to “OIL COOLER” on page 6-5.
Refer to “ELECTRIC STARTER” on page
Starter motor 5-30.
Water pump assembly Refer to “WATER PUMP” on page 6-9.
gear CLUTCH” on page 5-44.
Clutch assembly Refer to “CLUTCH” on page 5-51.
Oil pump assembly Refer to “OIL PUMP” on page 5-59.
Outer V-belt case/Primary sheave assem- Refer to “V-BELT AUTOMATIC TRANSMIS-
bly/Secondary sheave assembly/Inner V-belt SION” on page 5-34.
case
Bearing housing Refer to “SWINGARM” on page 4-106.
5-62
CRANKCASE
Separating the crankcase
7 4
10 N・m (1.0 kgf・m, 7.4 lb・ft)

(6) (8)
3
(5)
5
10 N・m (1.0 kgf・m, 7.4 lb・ft)

2 LT
(6)
LT
LT
(2) (4)
8
(4)
6
24 N・m (2.4 kgf・m, 18 lb・ft)
9
7 N・m (0.7 kgf・m, 5.2 lb・ft)

43 N・m (4.3 kgf・m, 32 lb・ft)
55 N・m (5.5 kgf・m, 41 lb・ft) 1

1 Centerstand assembly 1
2 Timing chain 1
3 Timing chain guide (intake side) 1
4 Crankcase (left) 1
5 Dowel pin 2
6 Oil strainer 1
7 Crankcase (right) 1
8 Centerstand lock solenoid cover 1
9 Centerstand lock solenoid 1
5-63
CRANKCASE
Removing the oil seals and bearings
E
E
3 1 3
3

Crankshaft assembly Refer to “CRANKSHAFT” on page 5-67.
Transmission Refer to “TRANSMISSION” on page 5-77.
1 Bearing retainer 2
2 Oil seal 2
3 Bearing 5
5-64
CRANKCASE
EAS30389 EAS30397
DISASSEMBLING THE CRANKCASE ASSEMBLING THE CRANKCASE

• Crankcase bolts • Cylinder stud bolts “1”
TIP TIP
Loosen each bolt 1/4 of a turn at a time, in stag- For the cylinder stud bolt, embedded height “a”
es and in a crisscross pattern. After all of the is the standard value and the tightening torque is
bolts are fully loosened, remove them. the reference value.
• M6  35 mm (1.38 in) bolts “1”
• M6  50 mm (1.97 in) bolts “2” Cylinder stud bolt
13 N·m (1.3 kgf·m, 9.6 lb·ft)
• M8  110 mm (4.33 in) bolts “3”
T.
R.
• M8  120 mm (4.72 in) bolts “4”
1
3 1 2
a
3
1
4
2
3
2 3 2 1
a. 150.2–152.2 mm (5.91–5.99 in)
2. Remove:
• Crankcase (left) 2. Thoroughly clean all the gasket mating sur-
ECA13900
faces and crankcase mating surfaces.
NOTICE 3. Apply:
Tap on one side of the crankcase with a soft- • Sealant
face hammer. Tap only on reinforced por- (onto the crankcase mating surfaces)
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully Yamaha bond No. 1215
and make sure the crankcase halves sepa- 90890-85505
rate evenly.
EAS30390 TIP
CHECKING THE CRANKCASE Do not allow any sealant to come into contact
1. Thoroughly wash the crankcase halves in a with the oil gallery.
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:
• Crankcase
• Oil delivery passages
EAS31445
CHECKING THE TIMING CHAIN

1. Check:
4. Install:
• Timing chain
• Dowel pins
Damage/stiffness  Replace the timing
• Crankcase (left)
chain, camshafts and crankshaft assembly
as a set.
5-65
CRANKCASE
5. Install:
• Crankcase bolts (M8)
• Crankcase bolts (M6)
Crankcase bolt (M8)
24 N·m (2.4 kgf·m, 18 lb·ft)
T.
Crankcase bolt (M6)

R.
10 N·m (1.0 kgf·m, 7.4 lb·ft)
TIP
Tighten each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern.
• M8  120 mm (4.72 in) bolts “1”
• M8  110 mm (4.33 in) bolts “2”
• M6  50 mm (1.97 in) bolts “3”
• M6  35 mm (1.38 in) bolts “4”
2 4 3
1
3
2
3 2 3 4
6. Check:
• Crankshaft and transmission operation
Rough movement  Repair.
5-66
CRANKSHAFT
EAS20061
CRANKSHAFT
Removing the crankshaft assembly
1st 16 N・m (1.6 kgf・m, 12 lb・ft)

2nd 58 N・m (5.8 kgf・m, 43 lb・ft)
E
LT
E
4 (4)
5 2
1
5
E

Separate.
Crankcase Refer to “CRANKCASE” on page 5-62.
1 Dowel pin 2
2 Balancer cylinder 1
3 Crankshaft assembly 1
4 Oil seal 1
5 Crankshaft journal bearing 2
5-67
CRANKSHAFT
Removing the connecting rods
E
7
1st 16 N・m (1.6 kgf・m, 12 lb・ft)
2nd Specified angle 90˚
5 E
M 6
E
5
M
11
1
2 10
M
8 E
E
4
E 1
9 2 M
3 E
M E
M
4
60 N・m (6.0 kgf・m, 44 lb・ft) 1st 16 N・m (1.6 kgf・m, 12 lb・ft)
M M
2nd Specified angle 90˚
3

1 Connecting rod cap 2
2 Big end lower bearing 2
3 Connecting rod 2
4 Big end upper bearing 2
5 Piston pin clip 2
6 Balancer piston pin 1
7 Balancer piston 1
8 Balancer connecting rod cap 1
9 Balancer big end lower bearing 1
10 Balancer connecting rod 1
11 Balancer big end upper bearing 1
5-68
CRANKSHAFT
EAS30415
REMOVING THE CONNECTING RODS

The following procedure applies to all of the con-
necting rods.
1. Remove:
• Connecting rod cap “1”
• Connecting rod “2”
• Big end bearings
TIP
Identify the position of each big end bearing so
that it can be reinstalled in its original place.
EAS30419 TIP
REMOVING THE CRANKSHAFT JOURNAL Identify the position of each crankshaft journal
BEARINGS bearing so that it can be reinstalled in its original
The following procedure applies to both of the place.
crankshaft journal bearings.
1. Remove: EAS30423
• Crankshaft assembly CHECKING THE CRANKSHAFT AND

• Crankshaft journal bearing “1” CONNECTING RODS
TIP 1. Measure:
Remove the crankshaft journal bearing using the • Crankshaft runout
plane bearing installer “2”. Out of specification  Replace the crank-
shaft.
Plane bearing installer Runout limit
90890-04139 0.030 mm (0.0012 in)
2. Check:
• Crankshaft journal surfaces
• Crankshaft pin surfaces
• Bearing surfaces
Scratches/wear  Replace the crankshaft.
3. Measure:
• Crankshaft-pin-to-big-end-bearing clearance
5-69
CRANKSHAFT
Out of specification  Replace the big end

bearings.
Connecting rod
Oil clearance
0.036–0.060 mm (0.0014–0.0024
in)
Balancer
Oil clearance
0.036–0.060 mm (0.0014–0.0024
in)
d. Assemble the connecting rod halves.
The following procedure applies to all of the TIP
connecting rods and balancer connecting • Do not move the connecting rod or crankshaft
rod. until the clearance measurement has been
ECA13930
completed.
NOTICE
• Lubricate the bolts threads and nut seats with
Do not interchange the big end bearings and molybdenum disulfide grease.
connecting rods. To obtain the correct • Make sure the “Y” mark “c” on the connecting
crankshaft-pin-to-big-end-bearing clear- rod faces towards the left side of the crank-
ance and prevent engine damage, the big shaft.
end bearings must be installed in their origi- • Make sure the characters “d” on both the con-
nal positions. necting rod and connecting rod cap are
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ aligned.
a. Clean the big end bearings, crankshaft pins,
and the inside of the connecting rod halves.
b. Install the big end upper bearing into the con-
necting rod and the big end lower bearing into
the connecting rod cap.
TIP
Align the projections “a” on the big end bearings
with the notches “b” in the connecting rod and
connecting rod cap.
e. Tighten the connecting rod nuts.

Refer to “INSTALLING THE CONNECTING
RODS” on page 5-73.
f. Remove the connecting rod and big end
bearings.
Refer to “REMOVING THE CONNECTING
RODS” on page 5-69.
g. Measure the compressed Plastigauge®
width “e” on the crankshaft pin.
c. Put a piece of Plastigauge® “1” on the crank- If the crankshaft-pin-to-big-end-bearing
shaft pin. clearance is out of specification, select re-
placement big end bearings.
5-70
CRANKSHAFT
spectively, then the bearing size for P1 is:

P1 (connecting rod) - P1 (crankshaft)
=5-1
= 4 (green)
Bearing color code

Code 1
Blue
Code 2
Black
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Code 3
Brown
4. Select:
Code 4
• Big end bearings (P1–P3) Green
TIP
• The numbers “A” stamped into the crankshaft 5. Measure:
web and the numbers “B” on the connecting • Crankshaft-journal-to-crankshaft-journal
rods are used to determine the replacement bearing clearance
big end bearing sizes. Out of specification  Replace the crank-
• P1–P3 refer to the bearings shown in the crankshaft journal bearings.
shaft illustration.
Journal oil clearance
0.040–0.087 mm (0.0016–0.0034
in)
TIP
On the journal, the larger value is used as a ba-
sis for calculation of the oil clearance, and on the
journal bearing, the smaller value is used.
ECA13920
NOTICE
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft-
journal-to-crankshaft-journal-bearing clear-
ance and prevent engine damage, the crank-
shaft journal bearings must be installed in
their original positions.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the crankshaft journal bearings, crank-
shaft journals, and bearing portions of the
crankcase.
b. Check the bearing surface. If the bearing sur-
face is worn or scratched, both bearings
should be replaced.
TIP
If either of the right or left journal bearing is worn
or scratched, both bearings should be replaced
as a set.
c. Measure the crankshaft journal diameter “a”
For example, if the connecting rod P1 and the of each crankshaft journal at two places. If it
crankshaft web P1 numbers are 5 and 1 re- is out of specification, replace the crankshaft.
5-71
CRANKSHAFT
Crankshaft journal diameter

54.984-55.000 mm (2.1647-
2.1654 in)
d. Measure the crankshaft journal bearing in-

side diameter “b” of each crankshaft journal
bearing at two places.
e. If crankshaft journal bearing inside diameter

is “55.03” and crankshaft journal diameter is
“54.98”, then the journal oil clearance is:
Journal oil clearance:
Crankshaft journal bearing inside diameter -
Crankshaft journal diameter
= 55.03 - 54.98
= 0.05 mm
If the oil clearance is out of specification, se-

lect replacement bearings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Select:
• Crankshaft journal bearings (J1–J2)
TIP For example, if the crankcase J1 and the
• The numbers “A” is stamped into the crank- crankshaft web J1 numbers are 4 and 2 re-
shaft web, the number “B” on the left crank- spectively, then the bearing size for J1 is:
case, and the number “C” on the right J1 (crankcase) - J1 (crankshaft web)
crankcase. =4-2
• The numbers “A”, “B”, and “C”are used to de- = 2 (black)
termine the replacement crankshaft journal
bearing size.
• J1–J2 refer to the bearings shown in the crank-
shaft illustration.
5-72
CRANKSHAFT
Bearing color code

Code 0
White
Code 1
Blue
Code 2
Black
Code 3
Brown
Code 4
Green
Code 5
Yellow
EAS31446
INSTALLING THE CRANKSHAFT JOURNAL

BEARINGS
1. Attach:
• Crankshaft journal bearing “1”
TIP
EAS30426
Attach the crankshaft journal bearing to the INSTALLING THE CONNECTING RODS
plane bearing installer “2”. 1. Lubricate:
• Bolt threads New
Plane bearing installer • Nut seats New
90890-04139 (with the recommended lubricant)
2. Install: Recommended lubricant
• Crankshaft journal bearing Molybdenum disulfide oil
TIP
• Align the projection “a” on the bearing with the 2. Lubricate:
projection “b” on the crankcase. • Crankshaft pins
• Place an iron plate “3” beneath the crankcase • Big end bearings inner surface
and press fit until the end of the plain bearing • Balancer big end bearings inner surface
installer touches the iron plate. (with the recommended lubricant)
Engine oil
3. Install:
• Big end bearings
• Connecting rods
• Connecting rod caps
(onto the crankshaft pins)
TIP
• Align the projections “a” on the big end bear-
ings with the notches “b” in the connecting rods
and connecting rod caps.
• Be sure to reinstall each big end bearing in its
original place.
• Make sure the “Y” marks “c” on the connecting
rods face towards the left side of the crank-
shaft.
5-73
CRANKSHAFT
• Make sure the characters “d” on both the con- c. Tighten the connecting rod nuts further to
necting rod and connecting rod cap are reach the specified angle 90.
aligned.
Connecting rod nut (2nd)
Specified angle 90
T.
R.
EWA13400
WARNING
If the connecting rod nut is tightened more
than the specified angle, do not loosen the
nut and then retighten it. Instead, replace the
connecting rod bolt and nut with a new one
and perform the procedure again.
ECA19930
4. Tighten: NOTICE
• Connecting rod nuts • Do not use a torque wrench to tighten the
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ connecting rod nut to the specified angle.
EWA13390
• Tighten the nut until it is at the specified an-
WARNING gle.
• Replace the connecting rod bolts and nuts
TIP
with new ones.
On a hexagonal nut, note that the angle from
• Clean the connecting rod bolts and nuts.
one corner to another is 60.
TIP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Tighten the connecting rod nuts using the follow-
ing procedure. 5. Install:
• Balancer big end bearings
a. Tighten the connecting rod nuts with a torque • Balancer connecting rod
wrench. • Balancer connecting rod cap
Connecting rod nut (1st) (onto the crankshaft pin)
16 N·m (1.6 kgf·m, 12 lb·ft) TIP
T.
• Align the projections “a” on the balancer big

R.
b. Put a mark “1” on the corner of the connecting end bearings with the notches “b” in the bal-
rod nut “2” and the connecting rod cap “3”. ancer connecting rod and balancer connecting
rod cap.
• Be sure to reinstall each balancer big end bear-
ing in its original place.
• Make sure the “Y” marks “c” on the balancer
connecting rod face towards the left side of the
crankshaft.
• Make sure the characters “d” on both the bal-
ancer connecting rod and balancer connecting
rod cap are aligned.
5-74
CRANKSHAFT
a 1
1
EAS30428
INSTALLING THE CRANKSHAFT

ASSEMBLY
1. Install:
• Crankshaft assembly “1”
• Balancer cylinder “2”
• Balancer cylinder bolt
ECA13970
NOTICE
To avoid scratching the crankshaft and to
6. Tighten: ease the installation procedure, lubricate the
• Balancer connecting rod nuts oil seal lips with lithium-soap-based grease
and each bearing with engine oil.
Balancer connecting rod nut
60 N·m (6.0 kgf·m, 44 lb·ft) TIP
T.
Tighten the balancer cylinder bolts in the tighten-

R.
ECA22190
ing sequence as shown and torque them in 2
NOTICE
stages.
When tightening the nuts, be sure to use an
F-type torque wrench. Balancer cylinder bolt
TIP 1st: 16 N·m (1.6 kgf·m, 12 lb·ft)
T.
2nd: 58 N·m (5.8 kgf·m, 43 lb·ft)

R.
Tighten the nuts to the specified torque. Apply

continuous torque between 30 N·m (3.0 kgf·m, LOCTITE®
22 lb·ft) and 60 N·m (6.0 kgf·m, 44 lb·ft) without
pausing. After reaching 30 N·m (3.0 kgf·m, 22
lb·ft), do not stop tightening until the specified
torque is achieved. If the tightening is interrupted
between 30 N·m (3.0 kgf·m, 22 lb·ft) and 60 N·m
(6.0 kgf·m, 44 lb·ft), loosen the nut to less than
30 N·m (3.0 kgf·m, 22 lb·ft) and start again. 2
7. Install:
• Balancer piston “1”
• Balancer piston pin 1
• Piston pin clip “2” New
TIP
• Apply engine oil onto the balancer piston pin.
• Make sure that the clip ends “a” are positioned
away from the cutout “b” in the balancer piston
as shown in the illustration.
5-75
CRANKSHAFT
1
4
3 2
2
5-76
TRANSMISSION
EAS20062
TRANSMISSION
Removing the transmission
5 3

Separate.
Crankcase Refer to “CRANKCASE” on page 5-62.
1 Secondary shaft 1
2 Collar 1
3 Primary driven gear 1
4 Main axle 1
5 1st pinion gear 1
6 Drive axle 1
7 1st wheel gear 1
8 Circlip 1
5-77
TRANSMISSION
EAS30433
CHECKING THE TRANSMISSION

1. Check:
• Transmission gears
Blue discoloration/pitting/wear  Replace.
2. Check:
• Transmission gear movement
Rough movement  Replace the defective
part(s).
3. Check:
• Main axle
Cracks/damage/wear  Replace the main
axle.
4. Measure:
• Drive axle runout
(with a centering device and dial gauge)
Out of specification  Replace the drive axle.
Drive axle runout limit
0.08 mm (0.0032 in)
5. Measure:
• Secondary shaft runout
(with a centering device and dial gauge)
Out of specification  Replace the second-
ary shaft.
Secondary shaft runout limit
0.12 mm (0.0047 in)
5-78
TRANSMISSION
5-79
COOLING SYSTEM
RADIATOR........................................................................................................6-1
CHECKING THE RADIATOR.....................................................................6-3
1
INSTALLING THE RADIATOR...................................................................6-3
OIL COOLER....................................................................................................6-5
CHECKING THE OIL COOLER .................................................................6-6
INSTALLING THE OIL COOLER ...............................................................6-6
THERMOSTAT..................................................................................................6-7 2
CHECKING THE THERMOSTAT...............................................................6-8
INSTALLING THE THERMOSTAT ASSEMBLY ........................................6-8
WATER PUMP ..................................................................................................6-9

DISASSEMBLING THE WATER PUMP...................................................6-11
3
CHECKING THE WATER PUMP .............................................................6-11
ASSEMBLING THE WATER PUMP.........................................................6-11
4
INSTALLING THE WATER PUMP ...........................................................6-12
5
6
7
8
9
RADIATOR
EAS20063
RADIATOR
Removing the radiator
13 N・m (1.3 kgf・m, 9.6 lb・ft) 6 7 N・m (0.7 kgf・m, 5.2 lb・ft)
3
2
LT
13 N・m (1.3 kgf・m, 9.6 lb・ft)
1 1
FW
D

panel/Front cowling assembly
Drain.
page 3-31.
1 Coolant reservoir hose 1
2 Coolant reservoir 1
3 Coolant reservoir cap 1
4 Coolant reservoir breather hose 1
TIP
5 Radiator cap 1 Remove/Install it with the radiator filler pipe
held.
6 Cooling system air bleed hose 1 Disconnect.
6-1
RADIATOR
Removing the radiator

LT
9
13 N・m (1.3 kgf・m, 9.6 lb・ft)
10
14
11
7
8
12
13 FW
D

7 Radiator filler pipe 1
8 Radiator filler hose 1
9 Radiator outlet hose 1 Disconnect.
10 Radiator inlet hose 1
11 Radiator fan motor coupler 1 Disconnect.
12 Radiator 1
13 Radiator fan 1
14 Radiator bracket 1
6-2
RADIATOR
EAS30439
CHECKING THE RADIATOR

1. Check:
• Radiator fins
Obstruction  Clean.
Apply compressed air to the rear of the radia-
tor.
Damage  Repair or replace.
TIP
Straighten any flattened fins with a thin, flathead
screwdriver.
b. Apply the specified pressure for ten seconds
and make sure there is no drop in pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Radiator fan
Damage  Replace.
Malfunction  Check and repair.
Refer to “COOLING SYSTEM” on page 8-47.
EAS30440
INSTALLING THE RADIATOR

1. Fill:
2. Check:
• Cooling system
• Radiator hoses
• Radiator pipes
mended coolant)
Refer to “CHANGING THE COOLANT” on
3. Measure:
page 3-31.
• Radiator cap valve opening pressure
2. Check:
Below the specified pressure  Replace the
• Cooling system
radiator cap.
Leaks  Repair or replace any faulty part.
Radiator cap valve opening pres- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
sure a. Attach the radiator cap tester “1” and radiator
107.9–137.3 kPa (1.08–1.37 cap tester adapter “2” to the radiator.
kgf/cm², 15.6–19.9 psi)
Radiator cap tester
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 90890-01325
a. Install the radiator cap tester “1” and radiator Mityvac cooling system tester kit
cap tester adapter “2” to the radiator cap “3”. YU-24460-A
Radiator cap tester adapter
Radiator cap tester 90890-01352
90890-01325 Pressure tester adapter
Mityvac cooling system tester kit YU-33984
YU-24460-A
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984 1
2
b. Apply 137.3 kPa (1.37 kgf/cm2, 19.9 psi) of
6-3
RADIATOR
pressure.
c. Measure the indicated pressure with the
gauge.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-4
OIL COOLER
EAS20064
OIL COOLER
Removing the oil cooler
D
FW
17 N・m (1.7 kgf・m, 13 lb・ft)
4
5 40 N・m (4.0 kgf・m, 30 lb・ft)

Bottom side cowling/Side panel/Radiator Refer to “GENERAL CHASSIS (1)” on page
cover/Bottom center cowling 4-1.
Drain.
page 3-28.
Drain.
page 3-31.
1 Oil filter cartridge 1
2 Oil cooler inlet hose 1
3 Oil cooler outlet hose 1
4 Oil filter cartridge union bolt 1
5 Oil cooler 1
6 Gasket 1
6-5
OIL COOLER
EAS30441
CHECKING THE OIL COOLER mended coolant)
1. Check: Refer to “CHANGING THE COOLANT” on
• Oil cooler page 3-31.
Cracks/damage  Replace. • Crankcase
2. Check: (with the specified amount of the recom-
• Oil cooler inlet hose mended engine oil)
• Oil cooler outlet hose Refer to “CHANGING THE ENGINE OIL” on
Cracks/damage/wear  Replace. page 3-28.
EAS30442 5. Check:
INSTALLING THE OIL COOLER • Cooling system
1. Clean: Leaks  Repair or replace any faulty part.
• Mating surfaces of the oil cooler and the Refer to “INSTALLING THE RADIATOR” on
crankcase page 6-3.
(with a cloth dampened with lacquer thinner) 6. Measure:
2. Install: • Radiator cap valve opening pressure
• Gasket New Below the specified pressure  Replace the
• Oil cooler “1” radiator cap.
• Oil filter cartridge union bolt “2” Refer to “CHECKING THE RADIATOR” on
page 6-3.
Oil filter cartridge union bolt
40 N·m (4.0 kgf·m, 30 lb·ft)
T.
R.
TIP
• Make sure that the gasket is positioned proper-
ly.
• Align the projection “a” on the oil cooler with the
slot “b” in the crankcase.
a 2
b
3. Install:
• Oil filter cartridge
Oil filter wrench
90890-01426
Oil filter wrench
YU-38411
Oil filter cartridge

17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.
Refer to “CHANGING THE ENGINE OIL” on

page 3-28.
4. Fill:
• Cooling system
6-6
THERMOSTAT
EAS20065
THERMOSTAT
Removing the thermostat
1
D
FW
3 10 N・m (1.0 kgf・m, 7.4 lb・ft)
4
2
6 5
7 N・m (0.7 kgf・m, 5.2 lb・ft)

cowling 4-1.
Drain.
page 3-31.
1 Cooling system air bleed hose 1 Disconnect.
2 Thermostat outlet hose 1 Disconnect.
3 Thermostat cover 1
4 Thermostat 1
5 Radiator fan motor coupler 1
6 Coolant pipe 1
6-7
THERMOSTAT
EAS30443
2. Check:
CHECKING THE THERMOSTAT • Thermostat cover
1. Check: Cracks/damage  Replace.
• Thermostat
Does not open at 71–85 C (159.8–185.0 F) EAS30445
 Replace. INSTALLING THE THERMOSTAT

ASSEMBLY
1. Install:
• Thermostat
TIP
Install the thermostat with its breather hole “a”
facing forward.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat “1” in a container “2”
filled with water.
a
b. Slowly heat the water “3”.
c. Place a thermometer “4” in the water.
d. While stirring the water, observe the thermo-
stat and thermometer’s indicated tempera- 2. Fill:
ture. • Cooling system
mended coolant)
page 3-31.
3. Check:
• Cooling system
Refer to “INSTALLING THE RADIATOR” on
page 6-3.
4. Measure:
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.
A. Fully closed
B. Fully open
TIP
If the accuracy of the thermostat is in doubt, re-
place it. A faulty thermostat could cause serious
overheating or overcooling.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-8
WATER PUMP
EAS20066
WATER PUMP
Removing the water pump
3.0 N・m (0.30 kgf・m, 2.2 lb・ft)
2
10
7 N・m (0.7 kgf・m, 5.2 lb・ft)

10 N・m (1.0 kgf・m, 7.4 lb・ft)
5 7
M
10 N・m (1.0 kgf・m, 7.4 lb・ft)

9
8

cowling 4-1.
Drain.
page 3-31.
1 V-belt case air filter element joint clamp 1 Loosen.
2 V-belt case air filter element (left) 1
3 Oil filler cap 1
4 Generator cover protector 1
5 Oil cooler inlet hose 1 Disconnect.
6 Coolant hose 1 Disconnect.
7 Radiator outlet hose 1 Disconnect.
8 Water pump inlet pipe 1
9 Water pump outlet pipe 1
10 Water pump assembly 1
6-9
WATER PUMP
Disassembling the water pump
2
5
6
E
4
7 1
M
(2)
3
10 N・m (1.0 kgf・m, 7.4 lb・ft)

1 Water pump housing cover 1
2 Circlip 1
3 Impeller shaft 1
4 Mechanical seal 1
5 Bearing 1
6 Oil seal 1
7 Water pump housing 1
6-10
WATER PUMP
EAS30446 EAS30447
DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP

• Mechanical seal (impeller side) “1” • Water pump housing cover “1”
(from the impeller, with a thin, flathead screw- • Water pump housing “2”
driver) • Impeller shaft “3”
TIP Cracks/damage/wear  Replace.
Do not scratch the impeller shaft.
2. Check:
• Water pump inlet pipe
2. Remove:
• Water pump outlet pipe
• Mechanical seal (housing side) “1”
TIP
Remove the mechanical seal (housing side) EAS30448
from the inside of the water pump housing. ASSEMBLING THE WATER PUMP
1. Install:
• Oil seal “1” New
• Bearing “2” New
(into the water pump housing)
TIP
• Before installing the oil seal, apply tap water or
coolant onto its outer surface.
• Install the oil seal with a socket that matches its
outside diameter.
• Install the oil seal from the inside of the water
pump housing.
3. Remove:
• Bearing “1” Installed depth of oil seal “a”
• Oil seal “2” 11.5 mm (0.45 in)
TIP
Remove the bearing and oil seal from the out-
side of the water pump housing.
New
New
2. Install:
• Mechanical seal (housing side) “1” New
(into the water pump housing “2”)
6-11
WATER PUMP
ECA20330 ECA20340
NOTICE NOTICE
Never lubricate the mechanical seal (hous- Make sure the mechanical seal (impeller
ing side) surface with oil or grease. side) is flush with the impeller.
TIP TIP
Use the special tool and a press to press the me- If the surface “a” of the mechanical seal (impeller
chanical seal (housing side) straight in until it side) that contacts the mechanical seal (housing
touches the water pump housing. side) is dirty, clean it.
Mechanical seal installer Impeller shaft tilt limit

90890-04132 0.15 mm (0.006 in)
Water pump seal installer
YM-33221-A
Middle driven shaft bearing driver
90890-04058
Middle drive bearing installer 40 &
50 mm
YM-04058
a
4
3 1. Straightedge
2. Impeller shaft
1 New EAS30449
INSTALLING THE WATER PUMP

2
1. Install:
• O-ring New
A. Push down • Water pump assembly
3. Mechanical seal installer TIP
4. Middle driven shaft bearing driver • Align the slit “a” on the impeller shaft with the
projection “b” on the oil pump shaft.
3. Install: • Lubricate the O-ring with a thin coat of lithium-
• Mechanical seal (impeller side) “1” New soap-based grease.
TIP
Before installing the mechanical seal (impeller
Water pump assembly bolt
side), apply tap water or coolant onto its outer 10 N·m (1.0 kgf·m, 7.4 lb·ft)
surface.
T.
R.
New
4. Measure: 2. Fill:
• Impeller shaft tilt • Cooling system
Out of specification  Repeat step (3) and (with the specified amount of the recom-
(4). mended coolant)
6-12
WATER PUMP

page 3-31.
3. Check:
• Cooling system
Refer to “INSTALLING THE RADIATOR” on
page 6-3.
4. Measure:
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.
6-13
FUEL SYSTEM
FUEL TANK ......................................................................................................7-1

REMOVING THE FUEL TANK ...................................................................7-3
1
REMOVING THE FUEL PUMP ..................................................................7-3
CHECKING THE FUEL PUMP BODY........................................................7-3
CHECKING THE FUEL PUMP OPERATION.............................................7-3
CHECKING THE ROLLOVER VALVE .......................................................7-3
INSTALLING THE FUEL PUMP.................................................................7-4
2
INSTALLING THE FUEL TANK..................................................................7-4
THROTTLE BODY ............................................................................................7-5

CHECKING THE INJECTORS (BEFORE REMOVING) ............................7-9
REMOVING THE FUEL HOSE (FUEL RAIL SIDE) ...................................7-9
3
REMOVING THE INJECTORS ..................................................................7-9
CHECKING THE INJECTORS ...................................................................7-9
CHECKING AND CLEANING THE THROTTLE BODIES..........................7-9
REPLACING THE THROTTLE BODIES ..................................................7-11
INSTALLING THE INJECTORS ...............................................................7-11
4
CHECKING THE INJECTOR PRESSURE...............................................7-11
CHECKING THE FUEL PRESSURE .......................................................7-12
INSTALLING THE FUEL HOSE (FUEL RAIL SIDE) ................................7-13
ADJUSTING THE THROTTLE POSITION SENSOR...............................7-13
5
6
7
8
9
FUEL TANK
EAS20067
FUEL TANK
Removing the fuel tank
10
5 8
7
6
4.0 N・m (0.40 kgf・m, 3.0 lb・ft)
2
4.0 N・m (0.40 kgf・m, 3.0 lb・ft)
FW 3
D 1
4
cowling 4-1.
1 Fuel tank overflow hose 1
2 Fuel tank breather hose 1 Disconnect.
3 Fuel pump coupler 1 Disconnect.
4 Fuel hose connector 1 Disconnect.
5 Fuel tank 1
6 Fuel pump bracket 1
7 Fuel pump 1
8 Fuel pump gasket 1
9 Fuel tank cap 1
10 Filler cover 1
7-1
FUEL TANK
Removing the rollover valve and canister
D
FW
7 N・m (0.7 kgf・m, 5.2 lb・ft)
3 6
5
4
2 8
7

cowling 4-1.
1 Canister breather hose 1
2 Canister purge hose (hose joint to canister) 1
Fuel tank breather hose (rollover valve to canis-
3 1
ter)
4 Rollover valve 1
Fuel tank breather hose (fuel tank to rollover
5 1
valve)
6 Canister bracket 1
7 Canister holder 1
8 Canister 1
7-2
FUEL TANK
EAS30450
4. Remove:
REMOVING THE FUEL TANK • Fuel tank
1. Extract the fuel in the fuel tank through the
TIP
fuel tank cap with a pump. Do not set the fuel tank down so that the instal-
2. Remove: lation surface of the fuel pump is directly under
• Bottom side cowling the tank. Be sure to lean the fuel tank in an up-
• Side panel right position.
Refer to “GENERAL CHASSIS (1)” on page EAS30451
4-1. REMOVING THE FUEL PUMP
• Center cover 1. Remove:
• Fuel tank cover assembly • Fuel pump bracket
• Side cover • Fuel pump
• Footboard • Fuel pump gasket
Refer to “GENERAL CHASSIS (2)” on page ECA14721
4-11. NOTICE
3. Disconnect: • Do not drop the fuel pump or give it a
• Fuel tank overflow hose strong shock.
• Fuel tank breather hose • Do not touch the base section of the fuel
• Fuel hose (fuel tank side) sender.
• Fuel pump coupler
EWA17320 EAS30454
WARNING CHECKING THE FUEL PUMP BODY

Cover fuel hose connections with a cloth 1. Check:
when disconnecting them. Residual pres- • Fuel pump body
sure in the fuel lines could cause fuel to Obstruction  Clean.
spurt out when removing the hose. Cracks/damage  Replace the fuel pump
ECA17490
assembly.
NOTICE EAS30455
Be sure to disconnect the fuel hose by hand. CHECKING THE FUEL PUMP OPERATION
Do not forcefully disconnect the hose with 1. Check:
tools. • Fuel pump operation
Refer to “CHECKING THE FUEL PRES-
TIP SURE” on page 7-12.
• To remove the fuel hose from the fuel pump,
slide the fuel hose connector cover “1” on the EAS30699
end of the hose in the direction of the arrow CHECKING THE ROLLOVER VALVE
shown, press the two buttons “2” on the sides 1. Check:
of the connector, and then remove the hose. • Rollover valve “1”
• Before removing the hose, place a few rags in Damage/faulty  Replace.
the area under where it will be removed. TIP
• It is prohibited to wear the cotton work gloves • Check that air flows smoothly only in the direc-
or equivalent coverings. tion of the arrow shown in the illustration.
• The rollover valve must be in an upright posi-
tion when checking the airflow.
7-3
FUEL TANK
TIP
• Install the fuel hose securely onto the fuel
pump until a distinct “click” is heard.
1 • To install the fuel hose onto the fuel pump,
slide the fuel hose connector cover “1” on the
end of the hose in the direction of the arrow
shown.
• It is prohibited to wear the cotton work gloves
or equivalent coverings.
EAS30456
INSTALLING THE FUEL PUMP

1. Install:
• Fuel pump gasket New
• Fuel pump
• Fuel pump bracket
Fuel pump bolt
4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.
TIP
• Do not damage the installation surfaces of the 2. Connect:
fuel tank when installing the fuel pump. • Fuel pump coupler
• Always use a new fuel pump gasket. • Fuel tank breather hose
• Install the fuel pump as shown in the illustra- • Fuel tank overflow hose
tion. 3. Install:
• Align projection “a” on the fuel pump with mark • Fuel tank
“b” of the fuel tank. Fuel tank bolt
• Tighten the fuel pump bolts in the proper tight- 10 N·m (1.0 kgf·m, 7.4 lb·ft)
ening sequence as shown.
T.
R.
4
2
5
a
b 1 3
A. Forward
EAS30457
INSTALLING THE FUEL TANK

1. Connect:
• Fuel hose (fuel tank side)
ECA17500
NOTICE
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
the correct position, otherwise the fuel hose
will not be properly installed.
7-4
THROTTLE BODY
EAS20070
THROTTLE BODY
Removing the air filter case
FW
D
1
34 N・m (3.4 kgf・m, 25 lb・ft)
1.8 N・m (0.18 kgf・m, 1.3 lb・ft)
5
2
6
3
3.0 N・m (0.30 kgf・m, 2.2 lb・ft)
3.0 N・m (0.30 kgf・m, 2.2 lb・ft)

Throttle body assembly Refer to “THROTTLE BODY” on page 7-5.
Front fender Refer to “FRONT FORK” on page 4-87.
1 Plate 1
2 Cylinder head breather hose 1
3 Air filter case joint clamp 2 Loosen.
4 Air filter case cover 1
5 Air filter element 1
6 Air filter case 1
7-5
THROTTLE BODY
Removing the throttle body
FW 3.5 N・m (0.35 kgf・m, 2.6 lb・ft) 2.0 N・m (0.20 kgf・m, 1.5 lb・ft)
D
6 2
4 9
3
7
3
5 1
(4)
14 N・m (1.4 kgf・m, 10 lb・ft)
3.0 N・m (0.30 kgf・m, 2.2 lb・ft)

Disconnect.
Air filter case Refer to “THROTTLE BODY” on page 7-5.
1 Throttle servo motor coupler 1 Disconnect.
2 Throttle position sensor coupler 1 Disconnect.
3 Throttle body joint clamp screw 4 Loosen.
4 Throttle body assembly 1
5 Throttle body joint 2
6 Intake air pressure sensor coupler 1 Disconnect.
7 Injector coupler 2 Disconnect.
8 Intake air pressure sensor hose 1
9 Intake air pressure sensor 1
7-6
THROTTLE BODY
Removing the throttle body
FW 3.5 N・m (0.35 kgf・m, 2.6 lb・ft) 2.0 N・m (0.20 kgf・m, 1.5 lb・ft)
D
13
14
(4)
10
11 12
14 N・m (1.4 kgf・m, 10 lb・ft)
3.0 N・m (0.30 kgf・m, 2.2 lb・ft)

10 Intake manifold 1
11 Gasket 2
12 Fuel hose 1
13 Fuel rail 1
14 Injector 2
7-7
THROTTLE BODY
Disassembling the throttle body assembly
3.5 N・m (0.35 kgf・m, 2.6 lb・ft)

1 Throttle position sensor 1
2 Canister purge hose 2
3 Hose joint 1
7-8
THROTTLE BODY
EAS30475
hose. Any remaining pressure in the fuel
CHECKING THE INJECTORS (BEFORE hose may cause the fuel to spray out. Place
REMOVING) a container or rag under the hose to catch
1. Check: any fuel that spills. Always clean up any
• Injectors spilt fuel immediately.
Use the diagnostic code numbers “36”–“37”. • Push the OFF/LOCK switch and disconnect
Refer to “SELF-DIAGNOSTIC FUNCTION the negative battery lead from the battery
AND DIAGNOSTIC CODE TABLE (ECU)” on terminal before removing the injectors.
page 9-5.
1. Remove:
EAS31158
• Fuel rail “1”
REMOVING THE FUEL HOSE (FUEL RAIL
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
SIDE)
1. Remove: a. Remove the fuel rail screws “2” as shown.
• Fuel tank
Refer to “REMOVING THE FUEL TANK” on 1
page 7-3.
2. Remove: 2
• Fuel hose (fuel rail side)
ECA17490
NOTICE
Be sure to disconnect the fuel hose by hand.
Do not forcefully disconnect the hose with
tools.
TIP ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• To remove the fuel hose from the fuel rail joint,
EAS30477
CHECKING THE INJECTORS
end of the hose in the direction of the arrow 1. Check:
shown, press the two buttons “2” on the sides • Injectors
of the connector, and then remove the hose.
Obstruction  Replace and check the fuel
• Before removing the hose, place a few rags in pump/fuel supply system.
the area under where it will be removed. Deposit  Replace.
Damage  Replace.
or equivalent coverings. 2. Check:
• Injector resistance
Refer to “CHECKING THE FUEL INJEC-
TOR” on page 8-249.
EAS30769
CHECKING AND CLEANING THE THROTTLE

BODIES
TIP
Clean the throttle bodies only if they cannot be
synchronized using the bypass air screws. Be-
fore cleaning the throttle bodies, check the fol-
EAS30476 lowing items:
REMOVING THE INJECTORS • Valve clearance
EWA20210
• Spark plugs
WARNING • Air filter element
• Check the injectors in a well-ventilated area • Throttle body joints
free of combustible materials. Make sure • Fuel hose
that there is no smoking or use of electric • Exhaust system
tools in the vicinity of the injectors. • Cylinder head breather hose
• Be careful when disconnecting the fuel
7-9
THROTTLE BODY
EWA17340
WARNING
If the throttle bodies are subjected to strong
shocks or dropped during cleaning, replace
them as a set.
1. Check: a
• Throttle bodies
Cracks/damage  Replace the throttle bod-
ies as a set.
2. Clean:
• Throttle bodies c. Hold the throttle valves in the open position.
ECA21540
EWA15940
NOTICE WARNING
• Observe the following precautions; other- When cleaning the throttle bodies, be careful
wise, the throttle bodies may not operate not to injure yourself on the throttle valves or
properly. other components of the throttle bodies.
• Do not subject the throttle bodies to exces- ECA20380
sive force. NOTICE
• Clean the throttle bodies in the recom-
• Do not open the throttle valves by supply-
mended cleaning solvent.
ing electrical power to the throttle bodies.
• Do not use any caustic carburetor cleaning
• Do not use tools to open the throttle valves
solution.
or to keep them in the open position.
• Do not apply cleaning solvent directly to
• Do not open the throttle valves quickly.
any plastic parts, sensors, or seals.
• Be careful not to remove the white paint
mark that identifies the standard throttle
body.
• Do not turn the bypass air screws “a”; oth-
erwise, the throttle body synchronization
will be affected.
Recommended cleaning solvent

Yamaha Oil & Brake Cleaner
d. Apply the recommended cleaning solvent to

the throttle valves and the inside of the throt-
tle bodies to remove any carbon deposits.
TIP
a • Do not allow any cleaning solvent to enter the
opening for the injectors.
• Do not apply any cleaning solvent to the por-
tions of the throttle valve shafts between the
throttle bodies.
e. Remove the carbon deposits from the inside
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
of each throttle body in a downward direction,
a. Place the throttle bodies on a flat surface with
from the air filter case side of the throttle body
the air filter case side facing up.
to the engine side.
b. Install the caps (895-14169-00) onto the hose ECA17590
fittings “a”. NOTICE

• Do not use a tool, such as a wire brush, to
remove the carbon deposits; otherwise, the
inside of the throttle bodies may be dam-
7-10
THROTTLE BODY
aged. TLE BODIES” on page 3-9.

• Do not allow carbon deposits or other for- 5. Place the vehicle on a maintenance stand so
eign materials to enter any of the passages that the rear wheel is elevated.
in each throttle body or in the space be- 6. Check:
tween the throttle valve shaft and the throt- • Engine idling speed
tle body. Start the engine, warm it up, and then mea-
f. After removing the carbon deposits, clean the sure the engine idling speed.
inside of the throttle bodies with the recom- Engine idling speed
mended cleaning solvent, and then dry the 1100–1300 r/min
throttle bodies using compressed air.
g. Make sure that there are no carbon deposits EAS30480
or other foreign materials in any of the pas- INSTALLING THE INJECTORS

ECA21550
sages “a” in each throttle body or in the space
NOTICE
“b” between the throttle valve shaft and the
throttle body. • Always use new O-rings.
• When installing the injectors, do not allow
a any foreign material to enter or adhere to
the injectors, fuel rails, or O-rings.
• Be careful not to twist or pinch the O-rings
when installing the injectors.
• When installing the injector, install it at the
same position as the removed cylinder.
• If an injector is subject to strong shocks or
excessive force, replace it.
b • If installing the original fuel rail and bolts,
remove the white paint marks using a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ cleaning solvent. Otherwise, paint chips on
3. Install the throttle bodies. the bolt seats could prevent the bolts from
4. Reset: being tightened to the specified torque.
• ISC (idle speed control) learning values 1. Install a new seal onto the end of each injec-
Use the diagnostic code number “67”. tor.
Refer to “SELF-DIAGNOSTIC FUNCTION 2. Install the injectors to the fuel rail, making
AND DIAGNOSTIC CODE TABLE (ECU)” on sure to install them in the correct direction.
page 9-5. 3. Install the injector assembly to the intake
5. Adjust: manifold.
• Throttle bodies synchronizing
Out of specification  Replace the throttle Fuel rail bolt
bodies. 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.
Refer to “SYNCHRONIZING THE THROT-

TLE BODIES” on page 3-9. 4. Check the injector pressure after the injectors
are installed.
EAS31160
Refer to “CHECKING THE INJECTOR
REPLACING THE THROTTLE BODIES PRESSURE” on page 7-11.
1. Remove the throttle bodies from the vehicle.
2. Install a new throttle bodies to the vehicle. EAS30481
3. Reset: CHECKING THE INJECTOR PRESSURE

• ISC (idle speed control) learning values TIP
Use the diagnostic code number “67”. • After installing the injectors, perform the follow-
Refer to “SELF-DIAGNOSTIC FUNCTION ing steps to check the injector pressure.
AND DIAGNOSTIC CODE TABLE (ECU)” on • Do not allow any foreign materials to enter the
page 9-5. fuel lines.
4. Adjust: 1. Check:
• Throttle bodies synchronizing • Injector pressure
Refer to “SYNCHRONIZING THE THROT-
7-11
THROTTLE BODY
EAS30482
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE FUEL PRESSURE
a. Connect the fuel injector pressure adapter “1”
1. Check:
to the fuel rail joint “2”, and then connect an
• Fuel pressure
air compressor “3” to the adapter.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b. Connect the pressure gauge “4” to the fuel in-
jector pressure adapter “1”. a. Remove the bottom side cowling, side panel
and bottom center cowling.
Pressure gauge Refer to “GENERAL CHASSIS (1)” on page
90890-03153 4-1.
Pressure gauge b. Remove the center cover, fuel tank cover as-
YU-03153 sembly, side cover and footboard.
Fuel injector pressure adapter Refer to “GENERAL CHASSIS (2)” on page
90890-03210 4-11.
Fuel injector pressure adapter
c. Remove the fuel tank bolt and hold up the fuel
YU-03210
tank.
d. Disconnect the fuel hose “1” from the fuel
pump.
Refer to “REMOVING THE FUEL TANK” on
page 7-3.
EWA17320
WARNING
Cover fuel hose connections with a cloth
when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to
spurt out when removing the hose.
ECA17490
c. Close the valve on the fuel injector pressure NOTICE

adapter. Be sure to disconnect the fuel hose by hand.
d. Apply air pressure with the air compressor. Do not forcefully disconnect the hose with
e. Open the valve on the fuel injector pressure tools.
adapter until the specified pressure is
reached.
Specified air pressure 1
490 kPa (5.0 kgf/cm², 71.1 psi)
ECA17600
NOTICE
Never exceed the specified air pressure or
damage could occur.
f. Close the valve on the fuel injector pressure
adapter.
e. Connect the pressure gauge “2” and fuel
g. Check that the specified air pressure is held
pressure adapter “3” to the fuel hose.
at least one minute.
Pressure drops  Check the pressure gauge Pressure gauge
and adapter. 90890-03153
Check the seals and O-rings and then rein- Pressure gauge
stall. YU-03153
Out of specification  Replace the fuel injec- Fuel pressure adapter
tors. 90890-03186
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Fuel pressure adapter
YM-03186
7-12
THROTTLE BODY
EAS30485
ADJUSTING THE THROTTLE POSITION

2 SENSOR
ECA17540
3
NOTICE
• Handle the throttle position sensor with
special care.
• Never subject the throttle position sensor
to strong shocks. If the throttle position
sensor is dropped, replace it.
1. Check:
f. Start the engine. • Throttle position sensor
g. Measure the fuel pressure. Refer to “CHECKING THE THROTTLE PO-
Faulty  Replace the fuel pump. SITION SENSOR” on page 8-246.
Fuel line pressure (at idle) 2. Adjust:
220–300 kPa (2.2–3.0 kgf/cm², • Throttle position sensor angle
31.9–43.5 psi) TIP
Before adjusting the throttle position sensor, the
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ throttle bodies must be removed.
EAS31159 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
INSTALLING THE FUEL HOSE (FUEL RAIL a. Temporary tighten the throttle position sensor
SIDE) screws.
1. Connect: b. Check that the throttle valves are fully closed.
• Fuel hose (fuel rail side) c. Connect the throttle position sensor to the
ECA17500
wire harness.
NOTICE d. Remove the protective cap “1”, and then con-
When installing the fuel hose, make sure that nect the Yamaha diagnostic tool to coupler.
it is securely connected, and that the fuel TIP
hose connector cover on the fuel hose is in For information about using the Yamaha diag-
the correct position, otherwise the fuel hose nostic tool, refer to the operation manual that is
will not be properly installed. included with the tool.
TIP
• Install the fuel hose securely onto the fuel rail
joint until a distinct “click” is heard.
• To install the fuel hose onto the fuel rail joint, 1
end of the hose in the direction of the arrow
shown.
or equivalent coverings.
e. Diagnostic code number “01” is selected.

f. Adjust the position of the throttle position sen-
sor angle so that 11–20 can appear in the
Yamaha diagnostic tool screen.
g. After adjusting the throttle position sensor an-
gle, tighten the throttle position sensor
screws “2”.
Throttle position sensor screw
3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.
7-13
THROTTLE BODY
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-14
THROTTLE BODY
7-15
ELECTRICAL SYSTEM
IGNITION SYSTEM ..........................................................................................8-1

CIRCUIT DIAGRAM ...................................................................................8-1
1
TROUBLESHOOTING ...............................................................................8-7
ELECTRIC STARTING SYSTEM .....................................................................8-9

CIRCUIT DIAGRAM ...................................................................................8-9
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .........................8-15
TROUBLESHOOTING .............................................................................8-17
2
CHARGING SYSTEM.....................................................................................8-19
CIRCUIT DIAGRAM .................................................................................8-19
LIGHTING SYSTEM .......................................................................................8-27

3
CIRCUIT DIAGRAM .................................................................................8-27
SIGNALING SYSTEM ....................................................................................8-35

CIRCUIT DIAGRAM .................................................................................8-35
4
COOLING SYSTEM........................................................................................8-47
CIRCUIT DIAGRAM .................................................................................8-47
5
6
FUEL INJECTION SYSTEM...........................................................................8-55
CIRCUIT DIAGRAM .................................................................................8-55
ECU SELF-DIAGNOSTIC FUNCTION.....................................................8-61
TROUBLESHOOTING METHOD.............................................................8-61
YAMAHA DIAGNOSTIC TOOL ................................................................8-62
7
TROUBLESHOOTING DETAILS (FAULT CODE) ...................................8-63
CRUISE CONTROL SYSTEM (for XP530D-A)............................................8-117

CIRCUIT DIAGRAM ...............................................................................8-117
CRUISE CONTROL CIRCUIT OPERATION..........................................8-119
BASIC INSTRUCTIONS FOR TROUBLESHOOTING ...........................8-121
BASIC PROCESS FOR TROUBLESHOOTING ....................................8-122
[A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR
8
LIGHT ....................................................................................................8-123
[B-1] DIAGNOSIS USING THE FAULT CODES ....................................8-123
9
[B-2] DIAGNOSIS USING THE MALFUNCTION HISTORY CODES.....8-133
[B-3] MALFUNCTION HISTORY IS NOT DISPLAYED..........................8-133
[C-1] DELETING THE FAULT CODES ..................................................8-133
[C-2] FINAL CHECK ...............................................................................8-133
FUEL PUMP SYSTEM..................................................................................8-135
CIRCUIT DIAGRAM ...............................................................................8-135
TROUBLESHOOTING ...........................................................................8-141
WINDSHIELD DRIVE SYSTEM (for XP530D-A) .........................................8-143

CIRCUIT DIAGRAM ...............................................................................8-143
GRIP WARMER SYSTEM (for XP530D-A)..................................................8-147

CIRCUIT DIAGRAM ...............................................................................8-147
SEAT HEATER SYSTEM (for XP530D-A) ...................................................8-151

CIRCUIT DIAGRAM ...............................................................................8-151
ABS (Anti-lock Brake System) ...................................................................8-157

CIRCUIT DIAGRAM ...............................................................................8-157
ABS COMPONENTS CHART ................................................................8-163
ABS COUPLER LOCATION CHART .....................................................8-165
MAINTENANCE OF THE ABS ECU ......................................................8-167
ABS TROUBLESHOOTING OUTLINE...................................................8-167
BASIC INSTRUCTIONS FOR TROUBLESHOOTING ...........................8-168
BASIC PROCESS FOR TROUBLESHOOTING ....................................8-169
[A] CHECKING THE ABS WARNING LIGHT.........................................8-170
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON............8-170
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON .............................8-170
[A-3] THE ABS WARNING LIGHT COMES ON .....................................8-170
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE
(The select unit screen does not appear.) .............................................8-171
[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE .......................8-171
[B-1] MALFUNCTION ARE CURRENTLY DETECTED .........................8-171
[B-2] DIAGNOSIS USING THE FAULT CODES ....................................8-171
[B-3] DELETING THE FAULT CODES...................................................8-191
[C-1] FINAL CHECK ...............................................................................8-191
SMART KEY SYSTEM .................................................................................8-193

CIRCUIT DIAGRAM ...............................................................................8-193
SMART KEY SYSTEM SELF-DIAGNOSIS............................................8-205
SMART KEY SYSTEM EMERGENCY MODE .......................................8-207
REGISTERING A SMART KEY..............................................................8-209
DISABLING A SMART KEY ...................................................................8-210
REPLACING THE REMOTE CONTROL UNIT, STEERING LOCK,
AND ECU ..............................................................................................8-211
REPLACING THE REMOTE CONTROL UNIT ......................................8-211
REPLACING THE STEERING LOCK UNIT ...........................................8-211
REPLACING THE ECU ..........................................................................8-211
REPLACEMENT PARTS LIST ...............................................................8-212
ELECTRICAL COMPONENTS.....................................................................8-215
CHECKING THE SWITCHES ................................................................8-221
CHECKING THE BULBS AND BULB SOCKETS ..................................8-228
CHECKING THE FUSES .......................................................................8-229
REPLACING THE ECU (Engine Control Unit) .......................................8-230
CHECKING AND CHARGING THE BATTERY......................................8-230
CHECKING THE RELAYS .....................................................................8-233
CHECKING THE DIODES......................................................................8-239
CHECKING THE SPARK PLUG CAPS..................................................8-240
CHECKING THE IGNITION COIL ..........................................................8-241
CHECKING THE IGNITION SPARK GAP..............................................8-241
CHECKING THE CRANKSHAFT POSITION SENSOR.........................8-242
CHECKING THE LEAN ANGLE SENSOR.............................................8-242
CHECKING THE STARTER MOTOR OPERATION ..............................8-243
CHECKING THE STATOR COIL ...........................................................8-243
CHECKING THE RECTIFIER/REGULATOR .........................................8-243
CHECKING THE FUEL SENDER ..........................................................8-244
CHECKING THE FUEL METER/FUEL LEVEL WARNING
INDICATOR ...........................................................................................8-244
CHECKING THE RADIATOR FAN MOTOR ..........................................8-245
CHECKING THE COOLANT TEMPERATURE SENSOR......................8-245
CHECKING THE THROTTLE POSITION SENSOR ..............................8-246
CHECKING THE ACCELERATOR POSITION SENSOR ......................8-246
CHECKING THE THROTTLE SERVO MOTOR ....................................8-247
CHECKING THE WINDSHIELD DRIVE UNIT (for XP530D-A)..............8-247
CHECKING THE GRIP WARMERS (for XP530D-A) .............................8-248
CHECKING THE SEAT HEATER (for XP530D-A).................................8-248
CHECKING THE INTAKE AIR PRESSURE SENSOR ..........................8-248
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ...................8-249
CHECKING THE FUEL INJECTOR .......................................................8-249
CHECKING THE SMART KEY BATTERY .............................................8-250
CHECKING THE BUZZER .....................................................................8-250
CHECKING THE SEAT/FUEL LID LOCK SOLENOID...........................8-250
CHECKING THE STORAGE COMPARTMENT LID LOCK
SOLENOID (for XP530-A/XP530D-A) ...................................................8-251
IGNITION SYSTEM
EAS20072
IGNITION SYSTEM
EAS30490
CIRCUIT DIAGRAM
XP530E-A
8-1
IGNITION SYSTEM
4. Joint coupler
5. Remote control unit
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
45.Diode 1
46.Sidestand relay
47.Diode 2
50.Sidestand switch
51.Handlebar switch (right)
52.Engine stop switch
89.ECU (Engine Control Unit)
90.Ignition coil
91.Spark plug
98.Lean angle sensor
A. Wire harness
B. Negative battery sub-wire harness
8-2
IGNITION SYSTEM
XP530-A
8-3
IGNITION SYSTEM
4. Joint coupler
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
45.Diode 1
46.Sidestand relay
47.Diode 2
50.Sidestand switch
95.Ignition coil
96.Spark plug
A. Wire harness
8-4
IGNITION SYSTEM
XP530D-A
8-5
IGNITION SYSTEM
4. Joint coupler
15.Battery
17.Main fuse
19.Engine ground
20.Signaling system fuse
21.Ignition fuse
26.Diode (fuse box)
40.Headlight relay (dimmer)
46.Diode 1
47.Sidestand relay
48.Diode 2
51.Sidestand switch
57.Brake light relay
85.Tracking system control unit
107.Ignition coil
108.Spark plug
A. Wire harness
8-6
IGNITION SYSTEM
EAS30492
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Front cowling assembly/Side panels
2. Center cover
3. Footboards/Side covers
4. Rear cowling (right)
1. Check the fuses.

(Main and ignition)
Replace the fuse(s).
Refer to “CHECKING THE FUSES” NG
on page 8-229.
OK
2. Check the battery.
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on NG • Recharge or replace the battery.
page 8-230.
OK
3. Check the spark plugs.
Refer to “CHECKING THE SPARK Re-gap or replace the spark plugs.
PLUGS” on page 3-5. NG
OK
4. Check the ignition spark gap.
Refer to “CHECKING THE IGNI- Ignition system is OK.
TION SPARK GAP” on page 8-241. OK
NG
5. Check the spark plug caps.
Refer to “CHECKING THE SPARK Replace the spark plug caps.
PLUG CAPS” on page 8-240. NG
OK
6. Check the ignition coil.
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 8-241. NG
OK
7. Check the ignition system relay.
Refer to “CHECKING THE RE- Replace the ignition system relay.
LAYS” on page 8-233. NG
OK
8. Check the diodes.
(Diode (fuse box) (for XP530D-A),
diode 1 and diode 2) Replace the diode(s).
Refer to “CHECKING THE DI- NG
ODES” on page 8-239.
OK
8-7
IGNITION SYSTEM
9. Check the starting circuit cut-off re-

lay.
Replace the starting circuit cut-off relay.
Refer to “CHECKING THE RE- NG
LAYS” on page 8-233.
OK
10.Check the sidestand relay.
Refer to “CHECKING THE RE- Replace the sidestand relay.
OK
11.Check the sidestand switch.
Refer to “CHECKING THE Replace the sidestand switch.
SWITCHES” on page 8-221. NG
OK
12.Check the engine stop switch.
The engine stop switch is faulty. Replace
Refer to “CHECKING THE
NG the handlebar switch (right).
SWITCHES” on page 8-221.
OK
13.Check the lean angle sensor.
Refer to “CHECKING THE LEAN Replace the lean angle sensor.
ANGLE SENSOR” on page 8-242. NG
OK
14.Check the crankshaft position sen-
sor.
Refer to “CHECKING THE CRANK- Replace the stator coil.
SHAFT POSITION SENSOR” on NG
page 8-242.
OK
15.Check the entire ignition system’s
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on NG ness.
page 8-1.
OK
Replace the ECU or remote control
unit.
8-8
ELECTRIC STARTING SYSTEM
EAS20073

EAS30493
CIRCUIT DIAGRAM
XP530E-A
8-9
4. Joint coupler
15.Battery
16.Starter relay
17.Main fuse
18.Starter motor
19.Engine ground
21.Ignition fuse
26.Diode (fuse box)
46.Sidestand relay
47.Diode 2
50.Sidestand switch
53.ON/start switch
55.Front brake light switch
62.Rear brake light switch
A. Wire harness
8-10
XP530-A
8-11
4. Joint coupler
15.Battery
16.Starter relay
17.Main fuse
18.Starter motor
19.Engine ground
21.Ignition fuse
26.Diode (fuse box)
46.Sidestand relay
47.Diode 2
50.Sidestand switch
53.ON/start switch
A. Wire harness
8-12
XP530D-A
8-13
4. Joint coupler
15.Battery
16.Starter relay
17.Main fuse
18.Starter motor
19.Engine ground
21.Ignition fuse
26.Diode (fuse box)
47.Sidestand relay
48.Diode 2
51.Sidestand switch
54.ON/start switch
75.Brake light fuse
A. Wire harness
8-14
EAS30494
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the engine stop switch is set to “ ” and pressing the ON/start switch for one second, the starter motor
can only operate if at least one of the following conditions is met:
• The front brake lever is pulled to the handlebar (the front brake light switch is closed) and the sides-
tand is up (the sidestand switch is closed).
• The rear brake lever is pulled to the handlebar (the rear brake light switch is closed) and the sidestand
is up (the sidestand switch is closed).
The starting circuit cut-off relay prevents the starter motor from operating when neither of these condi-
tions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the
starter motor. When at least one of the above conditions has been met, the starting circuit cut-off relay
is closed and the engine can be started by pressing the ON/start switch.
23
21
20
22 19
1
3 18
16
15
4
14 17
13
5 6
12
7 8
10
11
8-15
1. Battery
2. Main fuse
3. Ignition system relay
5. Signaling system fuse
6. Ignition fuse
9. Diode (fuse box)
11.ON/start switch
14.Diode 3
16.Fuel injection system fuse
17.Spark plug
18.Ignition coil
19.Diode 1
20.Sidestand switch
21.Sidestand relay
22.Starter relay
23.Starter motor
8-16
EAS30495
TROUBLESHOOTING
The starter motor fails to turn.
TIP
1. Front cowling assembly
2. Storage box
3. Fuel tank
4. Rear cover (right)
1. Check the fuses.

(Main, ignition and signaling sys-
tem) Replace the fuse(s).
on page 8-229.
OK
page 8-230.
OK
3. Check the starter motor operation.
Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION” on page OK with step (5).
8-243.
NG
4. Check the starter motor.
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-32. NG
OK
OK
(Diode (fuse box) and diode 2)
Replace the diode(s).
OK
7. Check the starting circuit cut-off re-
lay.
Replace the starting circuit cut-off relay.
OK
8. Check the sidestand relay.
Refer to “CHECKING THE RE- Replace the sidestand relay.
OK
8-17
9. Check the starter relay.

Refer to “CHECKING THE RE- Replace the starter relay.
OK
10.Check the engine stop switch.
OK
11.Check the sidestand switch.
Refer to “CHECKING THE Replace the sidestand switch.
OK
12.Check the front brake light switch.
Refer to “CHECKING THE Replace the front brake light switch.
OK
13.Check the rear brake light switch.
Refer to “CHECKING THE Replace the rear brake light switch.
OK
14.Check the ON/start switch.
The ON/start switch is faulty. Replace the
NG handlebar switch (right).
OK
15.Check the start diodes.
(Diode 1 and 3, and diode (fuse
box) (for XP530D-A)) Replace the diode(s).
OK
16.Check the entire starting system’s
page 8-9.
OK
Replace the remote control unit.
Refer to “SMART KEY SYSTEM” on
page 8-193.
8-18
CHARGING SYSTEM
EAS20074
CHARGING SYSTEM
EAS30496
CIRCUIT DIAGRAM
XP530E-A
8-19
CHARGING SYSTEM
4. Joint coupler
12.AC magneto
13.Rectifier/regulator
15.Battery
17.Main fuse
19.Engine ground
A. Wire harness
8-20
CHARGING SYSTEM
XP530-A
8-21
CHARGING SYSTEM
4. Joint coupler
12.AC magneto
15.Battery
17.Main fuse
19.Engine ground
A. Wire harness
8-22
CHARGING SYSTEM
XP530D-A
8-23
CHARGING SYSTEM
4. Joint coupler
12.AC magneto
15.Battery
17.Main fuse
19.Engine ground
A. Wire harness
8-24
CHARGING SYSTEM
EAS30497
TROUBLESHOOTING
The battery is not being charged.
TIP
2. Storage box
3. Fuel tank
4. Rear cover (right)
1. Check the fuse.

(Main)
Replace the fuse.
on page 8-229.
OK
page 8-230.
OK
3. Check the stator coil.
Refer to “CHECKING THE STA- Replace the stator coil.
TOR COIL” on page 8-243. NG
OK
4. Check the rectifier/regulator.
Refer to “CHECKING THE RECTI-
Replace the rectifier/regulator.
FIER/REGULATOR” on page NG
8-243.
OK
5. Check the entire charging system’s
page 8-19.
OK
The charging system circuit is OK.
8-25
CHARGING SYSTEM
8-26
LIGHTING SYSTEM
EAS20075
LIGHTING SYSTEM
EAS30498
CIRCUIT DIAGRAM
XP530E-A
8-27
LIGHTING SYSTEM
4. Joint coupler
10.Storage box light
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
22.Taillight fuse
30.Headlight fuse
35.Storage box light switch
39.Diode 3
41.Headlight control unit
42.Headlight (low)
43.Headlight (high)
44.Auxiliary light
57.Dimmer/pass switch
67.License plate light
68.Tail/brake light (left)
69.Tail/brake light (right)
75.Meter assembly
77.Meter light
84.High beam indicator light
86.Yamaha diagnostic tool coupler
A. Wire harness
C. Headlight sub-wire harness (headlight har-
ness)
D. Headlight sub-wire harness (front turn signal
light harness)
8-28
LIGHTING SYSTEM
XP530-A
8-29
LIGHTING SYSTEM
4. Joint coupler
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
22.Taillight fuse
30.Headlight fuse
39.Diode 3
42.Headlight (low)
43.Headlight (high)
44.Auxiliary light
77.Meter assembly
79.Meter light
A. Wire harness
ness)
light harness)
8-30
LIGHTING SYSTEM
XP530D-A
8-31
LIGHTING SYSTEM
4. Joint coupler
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
22.Taillight fuse
30.Headlight fuse
39.Diode 3
43.Headlight (low)
44.Headlight (high)
45.Auxiliary light
87.Meter assembly
89.Meter light
A. Wire harness
ness)
light harness)
8-32
LIGHTING SYSTEM
EAS30499
TROUBLESHOOTING
Any of the following fail to light: headlight, auxiliary light, high beam indicator light, tail/brake light, li-
cense plate light, meter light or storage box light.
TIP
2. Mudguard
1. Check the each bulbs and bulb

sockets condition.
Refer to “CHECKING THE BULBS Replace the bulb(s) and bulb socket.
AND BULB SOCKETS” on page NG
8-228.
OK
2. Check the fuses.
(Main, headlight, ignition, signaling
system and taillight) Replace the fuse(s).
on page 8-229.
OK
page 8-230.
OK
OK
5. Check the diode.
(Diode 3)
Replace the diode.
OK
6. Check the dimmer switch.
The dimmer switch is faulty. Replace the
NG handlebar switch (left).
OK
7. Check the pass switch.
The pass switch is faulty. Replace the
NG handlebar switch (left).
OK
8. Check the headlight relay (dimmer).
Refer to “CHECKING THE RE- Replace the headlight relay (dimmer).
OK
8-33
LIGHTING SYSTEM
9. Check the storage box light switch.

Refer to “CHECKING THE Replace the storage box light switch.
OK
10.Check the entire lighting system’s
page 8-27.
OK
Replace the ECU, headlight assem-
bly, remote control unit or meter as-
sembly.
8-34
SIGNALING SYSTEM
EAS20076
SIGNALING SYSTEM
EAS30500
CIRCUIT DIAGRAM
XP530E-A
8-35
SIGNALING SYSTEM
4. Joint coupler
8. Buzzer
15.Battery
17.Main fuse
19.Engine ground
25.Backup fuse
27.ABS motor fuse
28.ABS solenoid fuse
29.ABS ECU fuse
32.Electronic throttle valve fuse
45.Diode 1
50.Sidestand switch
54.Hazard switch
58.Horn switch
61.Turn signal switch
63.Front turn signal light (left)
64.Front turn signal light (right)
65.Rear turn signal light (left)
66.Rear turn signal light (right)
70.Diode 5
71.Horn
75.Meter assembly
78.Tachometer
79.Engine trouble warning light
80.Traction control system indicator light
81.Turn signal indicator light (left)
82.Turn signal indicator light (right)
85.Multi-function display
96.Intake air temperature sensor
105.Fuel sender
107.ABS ECU (Electronic Control Unit)
A. Wire harness
light harness)
8-36
SIGNALING SYSTEM
XP530-A
8-37
SIGNALING SYSTEM
4. Joint coupler
8. Buzzer
15.Battery
17.Main fuse
19.Engine ground
25.Backup fuse
27.ABS motor fuse
29.ABS ECU fuse
32.Electronic throttle valve fuse
45.Diode 1
50.Sidestand switch
54.Hazard switch
59.Horn switch
71.Diode 5
72.Horn
77.Meter assembly
80.Tachometer
110.Fuel sender
A. Wire harness
light harness)
8-38
SIGNALING SYSTEM
XP530D-A
8-39
SIGNALING SYSTEM
4. Joint coupler B. Negative battery sub-wire harness

5. Remote control unit D. Headlight sub-wire harness (front turn signal
8. Buzzer light harness)
15.Battery
17.Main fuse
19.Engine ground
25.Backup fuse
26.Diode (fuse box)
27.ABS motor fuse
29.ABS ECU fuse
46.Diode 1
51.Sidestand switch
55.Hazard switch
62.Horn switch
73.Diode 5
74.Horn
75.Brake light fuse
87.Meter assembly
90.Tachometer
122.Fuel sender
A. Wire harness
8-40
SIGNALING SYSTEM
EAS30501
TROUBLESHOOTING
• Any of the following fail to light: turn signal light, brake light or an indicator light.
• The horn fails to sound.
• The fuel meter fails to operate.
• The speedometer fails to operate.
• The buzzer fails to sound.
• The V-belt replacement meter fails to operate.
• The ambient temperature meter fails to operate.
• The coolant temperature meter fails to operate.
• The oil change meter fails to operate.
TIP
2. Storage box
3. Fuel tank
4. Footboards
1. Check the fuses.

(Main, signaling system, ABS mo-
tor, ABS solenoid, ABS ECU and
backup) NG
Refer to “CHECKING THE FUSES”
on page 8-229.
OK
page 8-230.
OK
OK
(Diode 1 and diode 5)
Replace the diode(s).
OK
5. Check the entire signaling system’s
page 8-35.
OK
This circuit is OK.
8-41
SIGNALING SYSTEM
Checking the signaling system

The horn fails to sound.
1. Check the horn switch.
The horn switch is faulty. Replace the han-
NG dlebar switch (left).
OK
page 8-35.
OK
Replace the horn or remote control
unit.
The tail/brake light fails to come on.

1. Check the front brake light switch.
Refer to “CHECKING THE Replace the front brake light switch.
OK
2. Check the rear brake light switch.
Refer to “CHECKING THE Replace the rear brake light switch.
OK
page 8-35.
OK
Replace the tail/brake light assembly
or remote control unit.
The turn signal light, turn signal indicator light or both fail to blink.
1. Check the turn signal switch.
The turn signal switch is faulty. Replace
NG the handlebar switch (left).
OK
2. Check the hazard switch.
The hazard switch is faulty. Replace the
OK
3. Check the turn signal/hazard relay.
Refer to “CHECKING THE RE- Replace the turn signal/hazard relay.
OK
8-42
SIGNALING SYSTEM

page 8-35.
OK
Replace the meter assembly or re-
mote control unit.
The fuel meter fails to operate.
1. Check the fuel sender.
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
SENDER” on page 8-244. NG
OK
page 8-35.
OK
Replace the meter assembly.
The coolant temperature meter fails to operate.

1. Check the coolant temperature sen-
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR” NG
on page 8-245.
OK
2. Check the entire signaling system
page 8-35.
OK
Replace the ECU or meter assembly.
The speedometer fails to operate.

1. Check the rear wheel sensor.
Refer to “MAINTENANCE OF THE
Replace the rear wheel sensor.
REAR WHEEL SENSOR AND NG
SENSOR ROTOR” on page 4-36.
OK
2. Check the entire wheel sensor wir-
Properly connect or replace the wire har-
ing.
NG ness.
Refer to TIP.
OK
Replace the hydraulic unit assembly,
ECU or meter assembly.
8-43
SIGNALING SYSTEM
TIP
Replace if there is an open or short circuit.
• Between rear wheel sensor coupler and ABS ECU coupler.
(Black–Black)
(White–White)
• Between ABS ECU coupler and ECU (engine control unit) coupler.
(White/Yellow–White/Yellow)
• Between ECU coupler and meter assembly coupler.
(Light green/Blue–Light green/Blue)
(Light green/White–Light green/White)
The tachometer fails to operate.
1. Check the crankshaft position sen-
sor.
Refer to “CHECKING THE CRANK- Replace the stator coil.
SHAFT POSITION SENSOR” on NG
page 8-242.
OK
page 8-35.
OK
The ambient temperature meter fails to operate.

1. Check the air temperature sensor.
Refer to “CHECKING THE INTAKE Replace the intake air temperature sen-
AIR TEMPERATURE SENSOR” on NG sor.
page 8-249.
OK
page 8-35.
OK
The V-belt replacement indicator fails to come on.

page 8-35.
OK
8-44
SIGNALING SYSTEM
The oil change indicator fails to come on.

page 8-35.
OK
The buzzer does not sound.

1. Check the buzzer.
Refer to “CHECKING THE BUZZ- Replace the buzzer.
ER” on page 8-250. NG
OK
page 8-35.
OK
Replace the remote control unit or
ECU.
8-45
SIGNALING SYSTEM
8-46
COOLING SYSTEM
EAS20077
COOLING SYSTEM
EAS30502
CIRCUIT DIAGRAM
XP530E-A
8-47
COOLING SYSTEM
4. Joint coupler
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
23.Radiator fan motor fuse
25.Backup fuse
75.Meter assembly
87.Radiator fan motor
A. Wire harness
8-48
COOLING SYSTEM
XP530-A
8-49
COOLING SYSTEM
4. Joint coupler
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
25.Backup fuse
77.Meter assembly
A. Wire harness
8-50
COOLING SYSTEM
XP530D-A
8-51
COOLING SYSTEM
4. Joint coupler
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
25.Backup fuse
87.Meter assembly
A. Wire harness
8-52
COOLING SYSTEM
EAS30503
TROUBLESHOOTING
TIP
2. Storage box
3. Fuel tank
4. Footboard (right)
1. Check the fuses.

(Main, ignition, radiator fan motor
and backup) Replace the fuse(s).
on page 8-229.
OK
page 8-230.
OK
OK
4. Check the radiator fan motor.
Refer to “CHECKING THE RADIA- Replace the radiator fan motor.
TOR FAN MOTOR” on page 8-245. NG
OK
5. Check the radiator fan motor relay.
Refer to “CHECKING THE RE- Replace the radiator fan motor relay.
OK
6. Check the coolant temperature sen-
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR” NG
on page 8-245.
OK
7. Check the entire cooling system’s
page 8-47.
OK
8-53
COOLING SYSTEM
8-54
FUEL INJECTION SYSTEM
EAS20078

EAS30504
CIRCUIT DIAGRAM
XP530E-A
8-55
4. Joint coupler C. Headlight sub-wire harness (headlight har-

5. Remote control unit ness)
11.Crankshaft position sensor D. Headlight sub-wire harness (front turn signal
light harness)
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
25.Backup fuse
27.ABS motor fuse
29.ABS ECU fuse
42.Headlight (low)
43.Headlight (high)
50.Sidestand switch
75.Meter assembly
90.Ignition coil
91.Spark plug
92.Grip warmer connector
93.Grip warmer (left) (OPTION)
94.Grip warmer (right) (OPTION)
97.Intake air pressure sensor
99.O2 sensor
100.Injector #1
101.Injector #2
103.Accelerator position sensor
106.Fuel pump
A. Wire harness
8-56
XP530-A
8-57
4. Joint coupler C. Headlight sub-wire harness (headlight har-

5. Remote control unit ness)
11.Crankshaft position sensor D. Headlight sub-wire harness (front turn signal
light harness)
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
25.Backup fuse
27.ABS motor fuse
29.ABS ECU fuse
42.Headlight (low)
43.Headlight (high)
50.Sidestand switch
77.Meter assembly
95.Ignition coil
96.Spark plug
98.Grip warmer (left) (OPTION)
99.Grip warmer (right) (OPTION)
104.O2 sensor
105.Injector #1
106.Injector #2
111.Fuel pump
A. Wire harness
8-58
XP530D-A
8-59
4. Joint coupler A. Wire harness

5. Remote control unit B. Negative battery sub-wire harness
11.Crankshaft position sensor C. Headlight sub-wire harness (headlight har-
14.Ignition system relay ness)
15.Battery D. Headlight sub-wire harness (front turn signal
light harness)
17.Main fuse
19.Engine ground
21.Ignition fuse
25.Backup fuse
27.ABS motor fuse
29.ABS ECU fuse
43.Headlight (low)
44.Headlight (high)
51.Sidestand switch
75.Brake light fuse
87.Meter assembly
107.Ignition coil
108.Spark plug
110.Grip warmer (left)
111.Grip warmer (right)
116.O2 sensor
117.Injector #1
118.Injector #2
123.Fuel pump
8-60
EAS30505
ECU SELF-DIAGNOSTIC FUNCTION

The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is
operating normally. If this function detects a malfunction in the system, it immediately operates the en-
gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider
that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code
number is stored in the memory of the ECU.
Checking the engine trouble warning light
The engine trouble warning light comes on for around 2 seconds after the ON/start switch is pushed to
ON. If the warning light does not come on, the warning light (LED) may be defective.
ECU detects an abnormal signal from a sensor
If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions that
are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue operating or stop operating, depending on the conditions.
EAS30506
TROUBLESHOOTING METHOD
The engine operation is not normal and the engine trouble warning light comes on.
1. Check:
• Fault code number
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the fault code numbers that have a condition of “Detected” using the Yamaha diagnostic tool.
b. Identify the faulty system with the fault code number.
c. Identify the probable cause of the malfunction.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check and repair the probable cause of the malfunction.

Fault code No. No fault code No.
Check and repair. Refer to “TROUBLESHOOTING Check and repair.

DETAILS (FAULT CODE)” on page 8-63.
Monitor the operation of the sensors and actuators in
the diagnostic mode. Refer to “TROUBLESHOOT-
ING DETAILS (FAULT CODE)” on page 8-63 and
“SELF-DIAGNOSTIC FUNCTION AND DIAGNOS-
TIC CODE TABLE (ECU)” on page 9-5.
3. Perform the reinstatement action for the fuel injection system.

Refer to “Confirmation of service completion” in the appropriate table in “TROUBLESHOOTING DE-
TAILS (FAULT CODE)” on page 8-63.
TIP
• If another fault code number is displayed, repeat steps (1) to (3) until no fault code number is dis-
played.
• Pushing the OFF/LOCK switch will not erase the malfunction history.
The engine operation is not normal, but the engine trouble warning light does not come on.
1. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to “DIAG-
NOSTIC CODE: SENSOR OPERATION TABLE” on page 9-12 and “DIAGNOSTIC CODE: ACTU-
ATOR OPERATION TABLE” on page 9-15.
8-61
01: Throttle position sensor signal 1

(throttle angle)
13: Throttle position sensor signal 2
(throttle angle)
14: Accelerator position sensor signal 1
(throttle angle)
15: Accelerator position sensor signal 2
(throttle angle)
30: Ignition coil
36: Injector #1
37: Injector #2
If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the
engine.
EAS30951
YAMAHA DIAGNOSTIC TOOL

This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is included
with the tool.
90890-03256
90890-03254
TIP
A generic scan tool can also be used to identify malfunctions.
OBD/ GST Leadwire kit

90890-03249
Features of the Yamaha diagnostic tool

You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional meth-
ods.
By connecting the adapter interface, which is connected to the USB port of a computer, to a vehicle’s
ECU using the communication cable, you can display information that is necessary for identifying mal-
functions and for maintenance to display on the computer. The displayed information includes the sen-
sor output data and information recorded in the ECU.
Functions of the Yamaha diagnostic tool
Diagnosis of malfunction: Fault codes recorded on the ECU are read, and the contents are dis-
played.
The freeze frame data (FFD) is the operation data when a malfunction
was detected. This data can be used to identify when the malfunction
occurred and check the engine conditions and running conditions when
it occurred.
Diagnosis of function: Check the operation of the output value of each sensor and actuator.
Dynamic inspection: Check the electric component condition automatically.
Active test: Manually adjust injection duration and/or switch some actuators for
troubleshooting.
Maintenance record: Store the inspection history into the Yamaha diagnostic tool application.
Recall search: Search the recall campaign information.
Monitoring: Displays a graph of sensor output values for actual operating condi-
tions.
8-62
Logging: Records and saves the sensor output value in actual driving conditions.
CO adjustment: Adjust the concentration of CO admissions during idling.
Reprogram ECU: If necessary, the ECU is rewritten using ECU rewrite data provided by
Yamaha.
Ignition timing adjustment, etc. cannot be changed from the vehicle’s
original state.
Writing VIN/frame number: Write the VIN/frame number in the ECU.
View logs: Displays the logging data.
However, the Yamaha diagnostic tool cannot be used to freely change the basic vehicle functions, such
as adjusting the ignition timing.
Connecting the Yamaha diagnostic tool
Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler.
EAS31791
TROUBLESHOOTING DETAILS (FAULT CODE)

This section describes the measures per fault code number displayed on the Yamaha diagnostic tool.
Check and service the items or components that are the probable cause of the malfunction following
the order given.
After the check and service of the malfunctioning part have been completed, delete the fault codes dis-
played on the Yamaha diagnostic tool according to the reinstatement method.
Fault code No.:
Fault code number displayed on the Yamaha diagnostic tool when the engine failed to work normally.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “SELF-DIAGNOS-
TIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU)” on page 9-5.
Parts connected to the ECU
The following parts are connected to the ECU.
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
• Crankshaft position sensor • O2 sensor
• Fuel injector #1 • Lean angle sensor
• Fuel injector #2 • ABS ECU (Electronic Control Unit)
• Ignition coil • Throttle servo motor
• Throttle position sensor • Ignition system relay
• Accelerator position sensor • Brake light relay
• Intake air pressure sensor • Radiator fan motor relay
• Coolant temperature sensor • Meter assembly
• Intake air temperature sensor
8-63
Fault code No. P0030

TIP
• If fault code numbers “P0030” and “P0112” are both indicated, take the actions specified for fault code
number “P0112” first.
Item O2 sensor heater: defective heater controller detected.
Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. —
Tool display —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item tion and check Maintenance job pletion
1 Connection of O2 sensor cou- Improperly connected  Con- Push the ON/start switch, and
pler. nect the coupler securely or then check the condition of the
Check the locking condition of replace the wire harness. fault code using the malfunction
the coupler. mode of the Yamaha diagnostic
Disconnect the coupler and tool.
check the pins (bent or broken Condition is “Recovered”  Go
terminals and locking condition to item 6 and finish the service.
of the pins). Condition is “Detected”  Start
the engine, and then check the
condition of the fault code.
Condition is “Recovered”  Go
to item 6 and finish the service.
Condition is “Detected”  Go to
item 2.
TIP
For this check, also set the
engine stop switch to “ON”.
8-64
2 Connection of wire harness Improperly connected  Con- Push the ON/start switch, and
ECU coupler. nect the coupler securely or then check the condition of the
of the pins). Condition is “Detected”  Start
item 3.
TIP
3 Wire harness continuity. Open or short circuit  Properly Push the ON/start switch, and
connect or replace the wire har- then check the condition of the
ness. fault code using the malfunction
Between O2 sensor coupler and mode of the Yamaha diagnostic
ECU coupler. tool.
black–black Condition is “Recovered”  Go
Between joint coupler and fuel to item 6 and finish the service.
injection system relay. Condition is “Detected”  Start
red/blue–red/blue the engine, and then check the
item 4.
TIP
4 Defective O2 sensor heater. Replace the O2 sensor. Push the ON/start switch, and
then check the condition of the
fault code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is “Detected”  Start
item 5.
TIP
5 Malfunction in ECU. Replace the ECU. Service is finished.

Refer to “REPLACING THE
ECU (Engine Control Unit)” on
page 8-230.
8-65
6 Delete the fault code and check Confirm that the fault code has
that the engine trouble warning a condition of “Recovered”
light goes off. using the Yamaha diagnostic
tool, and then delete the fault
code.
Fault code No. P0107, P0108

[P0107] Intake air pressure sensor: ground short circuit detected.

Item [P0108] Intake air pressure sensor: open or power short circuit
detected.

Fail-safe system
Diagnostic code No. 03
Tool display Displays the intake air pressure.
Procedure Operate the throttle while pushing the “ ” side of the engine stop switch.
(If the display value changes, the performance is OK.)
Item Maintenance job
tion and check pletion
1 Connection of intake air pres- Improperly connected  Con- Push the ON/start switch, and
sure sensor coupler. nect the coupler securely or then check the condition of the
of the pins). Condition is “Detected”  Go to
item 2.
2 Connection of ECU coupler. Improperly connected  Con- Push the ON/start switch, and
Check the locking condition of nect the coupler securely or then check the condition of the
the coupler. replace the wire harness. fault code using the malfunction
Disconnect the coupler and mode of the Yamaha diagnostic
check the pins (bent or broken tool.
terminals and locking condition Condition is “Recovered”  Go
of the pins). to item 7 and finish the service.
item 3.
3 Wire harness continuity. Open or short circuit  Replace Push the ON/start switch, and
the wire harness. then check the condition of the
tool.
item 4.
8-66

detected.
3-1
2
1 5V 5V
L
3 L
P/W
4 P/W
B/L
5 B/L

2. ECU
3. Sensor input lead
4. Sensor output lead
5. Sensor ground lead
3-2 Disconnect the ECU coupler from the ECU.
Disconnect the intake air pressure sensor coupler from the intake air pressure sensor.
3-3 [For P0107] Ground short circuit
Between intake air pressure sensor coupler and ground: pink/white–ground
If there is continuity, replace the wire harness.
B/L P/W L
3-4 [For P0108] Open circuit

Between intake air pressure sensor coupler and ECU coupler: blue–blue
If there is no continuity, replace the wire harness.
B/L P/W L B/L P/W L B/L P/W L
O B R/B G Y/W Y/R R/L R R/W O B R/B G Y/W Y/R R/L R R/W O B R/B G Y/W Y/R R/L R R/W
Y/W B G/B B Y/W B G/B B Y/W B G/B B
Y/R L/Y G L B/W Y/R L/Y G L B/W Y/R L/Y G L B/W
A. XP530E-A
B. XP530-A
C. XP530D-A
8-67

detected.

Between intake air pressure sensor coupler and ECU coupler: pink/white–pink/white
Y/R R/L B/Y W W G/R Lg/L Y/R R/L B/Y W W G/R Lg/L Y/R R/L O/W B/Y W W G/R Lg/L
Lg L/W R B Br/W Lg/W Lg L/W R B Br/W Lg/W Lg L/W R/G G/L R B Br/W Lg/W
B/L B/W P/W L L B/L B/W W/G P/W L L B/L B/W W/G Lg/L P/W L L
B/L B/L Y/L W/G W/Y Gy/G Y/G B/L B/L Y/L W/G W/Y Gy/G Y/G B/L B/L Lg/B Y/L W/G W/Y Gy/G Y/G
A. XP530E-A
B. XP530-A
C. XP530D-A
Between intake air pressure sensor coupler and ECU coupler: black/blue–black/blue
A. XP530E-A
B. XP530-A
C. XP530D-A
3-7 Disconnect the couplers from the parts that are connected to the ECU.
Refer to “Parts connected to the ECU” on page 8-63.
8-68

detected.
3-8 [For P0107/P0108] Short circuit

Between intake air pressure sensor output terminal (pink/white) “a” of ECU coupler and any other
ECU coupler terminal “b”.
a a a
b b b
A. XP530E-A
B. XP530-A
C. XP530D-A
4 Installed condition of intake air Check for looseness or pinch- Push the ON/start switch, and
pressure sensor. ing. then check the condition of the
Improperly installed sensor  fault code using the malfunction
Reinstall or replace the sensor. mode of the Yamaha diagnostic
tool.
item 5.
8-69

detected.
5 Defective intake air pressure Execute the diagnostic mode. Crank the engine, and then
sensor. (Code No. 03) check the condition of the fault
When engine is stopped: code using the malfunction
Atmospheric pressure at the mode of the Yamaha diagnostic
current altitude and weather tool.
conditions is indicated. Condition is “Recovered”  Go
At sea level: Approx. 101 kPa to item 7 and finish the service.
(757.6 mmHg, 29.8 inHg), Condition is “Detected”  Go to
approx. 3.64 V item 6.
1000 m (3300 ft) above sea
level: Approx. 90 kPa (675.1
mmHg, 26.6 inHg), approx. 3.30
V
V
V
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking 
Check the intake air pressure
sensor.
Replace if defective.
page 8-230.
page 8-230.
code.
8-70

TIP
Perform this procedure when the engine is cold.
[P0112] Intake air temperature sensor: ground short circuit

Item detected.
[P0113] Intake air temperature sensor: open or power short circuit
detected.

Fail-safe system
Tool display Displays the air temperature.
Compare the actually measured air temperature with the tool display
Procedure
value.
1 Connection of intake air temper- Improperly connected  Con- Push the ON/start switch, and
ature sensor coupler. nect the coupler securely or then check the condition of the
item 2.
item 3.
tool.
item 4.
8-71

detected.
Item
detected.
3-1
2
5V
1
Br/W
3 Br/W
B/L B/L
4
1. Intake air temperature sensor

2. ECU
Disconnect the intake air temperature sensor coupler from the intake air temperature sensor.
Between intake air temperature sensor coupler and ground: brown/white–ground
Br/W B/L

Between intake air temperature sensor coupler and ECU coupler: brown/white–brown/white
Br/W B/L Br/W B/L Br/W B/L
A. XP530E-A
B. XP530-A
C. XP530D-A
8-72

detected.
Item
detected.

Between intake air temperature sensor coupler and ECU coupler: black/blue–black/blue
Br/W B/L Br/W B/L Br/W B/L
A. XP530E-A
B. XP530-A
C. XP530D-A
Between intake air temperature sensor output terminal (brown/white) “a” of ECU coupler and any
other ECU coupler terminal “b”.
a a a
b b b
A. XP530E-A
B. XP530-A
C. XP530D-A
4 Installed condition of intake air Check for looseness or pinch- Push the ON/start switch, and
temperature sensor. ing. then check the condition of the
tool.
item 5.
8-73

detected.
Item
detected.
5 Defective intake air tempera- Execute the diagnostic mode. Push the ON/start switch, and
ture sensor. (Code No. 05) then check the condition of the
When engine is cold: fault code using the malfunction
Displayed temperature is close mode of the Yamaha diagnostic
to the ambient temperature. tool.
The displayed temperature is Condition is “Recovered”  Go
not close to the ambient temper- to item 7 and finish the service.
ature  Check the intake air Condition is “Detected”  Go to
temperature sensor. item 6.
INTAKE AIR TEMPERATURE
SENSOR” on page 8-249.
page 8-230.
code.

TIP
Perform this procedure when the engine is cold.
[P0117] Coolant temperature sensor: ground short circuit detected.

Item [P0118] Coolant temperature sensor: open or power short circuit
detected.

Fail-safe system
When engine is cold: Displays temperature closer to air temperature.
Tool display
When engine is hot: Displays current coolant temperature.
Compare the actually measured coolant temperature with the tool display
Procedure
value.
Item Probable cause of malfunc- Maintenance job Confirmation of service com-

1 Connection of coolant tempera- Improperly connected  Con- Push the ON/start switch, and
ture sensor coupler. nect the coupler securely or then check the condition of the
item 2.
8-74

detected.
item 3.
tool.
item 4.
3-1
2
5V
1
3 3
G/R G/R
B/L B/L
4 4
1. Coolant temperature sensor

2. ECU
Disconnect the coolant temperature sensor coupler from the coolant temperature sensor.
Between wire harness coupler (ECU side) and ground: green/red–ground
G/R B/L
8-75

detected.

Between wire harness coupler (ECU side) and ECU coupler: green/red–green/red
G/R B/L G/R B/L G/R B/L
A. XP530E-A
B. XP530-A
C. XP530D-A
Between wire harness coupler (ECU side) and ECU coupler: black/blue–black/blue
G/R B/L G/R B/L G/R B/L
A. XP530E-A
B. XP530-A
C. XP530D-A
8-76

detected.

Between wire harness (ECU side) output terminal (green/red) “a” of ECU coupler and any other ECU
coupler terminal “b”.
a a a
b b b
A. XP530E-A
B. XP530-A
C. XP530D-A
4 Installed condition of coolant Check for looseness or pinch- Push the ON/start switch, and
temperature sensor. ing. then check the condition of the
tool.
item 5.
5 Defective coolant temperature Execute the diagnostic mode. Push the ON/start switch, and
sensor. (Code No. 06) then check the condition of the
When engine is cold: fault code using the malfunction
Displayed temperature is close mode of the Yamaha diagnostic
to the ambient temperature. tool.
The displayed temperature is Condition is “Recovered”  Go
not close to the ambient temper- to item 7 and finish the service.
ature  Check the coolant tem- Condition is “Detected”  Go to
perature sensor. item 6.
COOLANT TEMPERATURE
SENSOR” on page 8-245.
page 8-230.
code.
8-77
Fault code No. P0122, P0123, P0222, P0223, P2135

TIP
If a fault code other than No. “P2135” (“P0122, P0123, P0222, P0223”) is detected, perform trouble-
shooting first.
[P0122] Throttle position sensor: ground short circuit detected.

[P0123] Throttle position sensor: open or power short circuit
detected.
Item [P0222] Throttle position sensor: ground short circuit detected.
detected.
[P2135] Throttle position sensor: output voltage deviation error.
Able/Unable to start engine

Fail-safe system
Able/Unable to drive vehicle
Diagnostic code No. 01, 13
Throttle position sensor signal 1
Tool display • 11–20 (fully closed position)
01 • 95–106 (fully open position)
Procedure • Check with throttle valves fully closed.

• Check with throttle valves fully open.
Throttle position sensor signal 2
Procedure • Check with throttle valves fully closed.

• Check with throttle valves fully open.
1 Connection of throttle position Improperly connected  Con- Push the ON/start switch, and
sensor coupler. nect the coupler securely or then check the condition of the
item 2.
item 3.
tool.
item 4.
8-78

detected.
detected.
3-1
2
1 5V 5V
L
3 L
W
4 W
5V
B
5 B
B/L
6 B/L

2. ECU
4. Sensor output lead 1
Disconnect the throttle position sensor coupler from the throttle position sensor.
Between throttle position sensor coupler and ground: white–ground
8-79

detected.
detected.

Between throttle position sensor coupler and ECU coupler: white–white
A. XP530E-A
B. XP530-A
C. XP530D-A
Between throttle position sensor coupler and ground: black–ground

Between throttle position sensor coupler and ECU coupler: black–black
A. XP530E-A
B. XP530-A
C. XP530D-A
8-80

detected.
detected.
3-7 [For P0123/P0223] Open circuit

Between throttle position sensor coupler and ECU coupler: blue–blue
A. XP530E-A
B. XP530-A
C. XP530D-A
Between throttle position sensor coupler and ECU coupler: black/blue–black/blue
A. XP530E-A
B. XP530-A
C. XP530D-A
8-81

detected.
detected.

Between throttle position sensor output terminal (white) “a” of ECU coupler and any other ECU cou-
pler terminal “b”.
a a a
b b b
A. XP530E-A
B. XP530-A
C. XP530D-A
Between throttle position sensor output terminal (black) “a” of ECU coupler and any other ECU cou-
pler terminal “b”.
a a a
b b b
A. XP530E-A
B. XP530-A
C. XP530D-A
4 Installed condition of throttle Check for looseness or pinch- Push the ON/start switch, and
position sensor. ing. then check the condition of the
Reinstall or adjust the sensor. mode of the Yamaha diagnostic
Refer to “ADJUSTING THE tool.
THROTTLE POSITION SEN- Condition is “Recovered”  Go
SOR” on page 7-13. to item 8 and finish the service.
item 5.
8-82

detected.
detected.
5 Defective throttle position sen- Measure the throttle position Push the ON/start switch, and
sor (resistance). sensor resistance. then check the condition of the
Refer to “CHECKING THE fault code using the malfunction
THROTTLE POSITION SEN- mode of the Yamaha diagnostic
SOR” on page 8-246. tool.
item 6.
6 Defective throttle position sen- Check throttle position sensor Push the ON/start switch, and
sor. signal 1. then check the condition of the
Execute the diagnostic mode. fault code using the malfunction
(Code No. 01) mode of the Yamaha diagnostic
When the throttle valves are tool.
fully closed: Condition is “Recovered”  Go
A value of 11–20 is indicated. to item 8 and finish the service.
When throttle valves are fully Condition is “Detected”  Go to
open: item 7.
A value of 95–106 is indicated.
Check throttle position sensor
signal 2.
Execute the diagnostic mode.
(Code No. 13)
When the throttle valves are
fully closed:
When the throttle valves are
fully open:
An indicated value is out of the
specified range  Replace the
throttle position sensor.
page 8-230.
code.
8-83

Item O2 sensor: short circuit detected (power short circuit).

Fail-safe system
Tool display —
Procedure —

1 Installed condition of O2 sensor. Check for looseness or pinch- Push the ON/start switch, and
ing. then check the condition of the
tool.
item 2.
2 Connection of O2 sensor cou- Improperly connected  Con- Push the ON/start switch, and
item 3.
item 4.
4 Wire harness continuity. Open or short circuit  Properly Push the ON/start switch, and
connect or replace the wire har- then check the condition of the
ness. fault code using the malfunction
Between O2 sensor coupler and mode of the Yamaha diagnostic
joint connector. tool.
black/blue–black/blue Condition is “Recovered”  Go
Between joint connector and to item 7 and finish the service.
ECU coupler. Condition is “Detected”  Go to
black/blue–black/blue item 5.
Between O2 sensor coupler and
ECU coupler.
gray/green–gray/green
8-84
Item O2 sensor: short circuit detected (power short circuit).
5 Defective O2 sensor. Check the O2 sensor. Push the ON/start switch, and
Defective  Replace the O2 then check the condition of the
sensor. fault code using the malfunction
Refer to “ENGINE REMOVAL” mode of the Yamaha diagnostic
on page 5-2. tool.
item 6.
page 8-230.
code.

Item Fuel injector #1: malfunction in fuel injector #1.
Able to start engine (depending on the number of faulty cylinders)

Fail-safe system
Able to drive vehicle (depending on the number of faulty cylinders)
Actuates fuel injector #1 five times at one-second intervals.
Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on
each time the fuel injector is actuated.
Disconnect the fuel pump coupler. Check that fuel injector #1 is actuated
Procedure
five times by listening for the operating sound.
1 Connection of fuel injector #1 Improperly connected  Con- Execute the diagnostic mode.
coupler. nect the coupler securely or (Code No. 36)
Check the locking condition of replace the wire harness. Operating sound  Go to item
the coupler. 6.
Disconnect the coupler and No operating sound  Go to
check the pins (bent or broken item 2.
terminals and locking condition
of the pins).
2 Defective fuel injector #1. Measure the fuel injector resis- Execute the diagnostic mode.
tance. (Code No. 36)
Replace if out of specification. Operating sound  Go to item
Refer to “CHECKING THE 6.
FUEL INJECTOR” on page No operating sound  Go to
8-249. item 3.
8-85
3 Connection of ECU coupler. Improperly connected  Con- Execute the diagnostic mode.
Check the locking condition of nect the coupler securely or (Code No. 36)
the coupler. replace the wire harness. Operating sound  Go to item
Disconnect the coupler and 6.
check the pins (bent or broken No operating sound  Go to
terminals and locking condition item 4.
of the pins).
4 Wire harness continuity. Open or short circuit  Replace Execute the diagnostic mode.
the wire harness. (Code No. 36)
Between fuel injector coupler Operating sound  Go to item
and ECU coupler. 6.
red/black–red/black No operating sound  Go to
Between fuel injector coupler item 5.
and starting circuit cut-off relay
coupler.
red/blue–red/blue
5 Malfunction in ECU. Replace the ECU.
page 8-230.
6 Delete the fault code and check Start the engine and let it idle for
that the engine trouble warning approximately 5 seconds.
light goes off. Confirm that the fault code has
a condition of “Recovered”
using the malfunction mode of
the Yamaha diagnostic tool, and
then delete the fault code.


Fail-safe system
Actuates fuel injector #2 five times at one-second intervals.
each time the fuel injector is actuated.
Disconnect the fuel pump coupler. Check that fuel injector #2 is actuated
Procedure
five times by listening for the operating sound.

1 Connection of fuel injector #2 Improperly connected  Con- Execute the diagnostic mode.
coupler. nect the coupler securely or (Code No. 37)
Check the locking condition of replace the wire harness. Operating sound  Go to item
the coupler. 6.
Disconnect the coupler and No operating sound  Go to
check the pins (bent or broken item 2.
terminals and locking condition
of the pins).
8-86
2 Defective fuel injector #2. Measure the fuel injector resis- Execute the diagnostic mode.
tance. (Code No. 37)
Replace if out of specification. Operating sound  Go to item
Refer to “CHECKING THE 6.
FUEL INJECTOR” on page No operating sound  Go to
8-249. item 3.
the coupler. replace the wire harness. Operating sound  Go to item
Disconnect the coupler and 6.
check the pins (bent or broken No operating sound  Go to
terminals and locking condition item 4.
of the pins).
Between fuel injector coupler Operating sound  Go to item
and ECU coupler. 6.
green/black–green/black No operating sound  Go to
Between fuel injector coupler item 5.
and starting circuit cut-off relay
coupler.
red/blue–red/blue
5 Malfunction in ECU. Replace the ECU.
page 8-230.
6 Delete the fault code and check Start the engine and let it idle for
that the engine trouble warning approximately 5 seconds.
light goes off. Confirm that the fault code has

Crankshaft position sensor: no normal signals are received from

Item
the crankshaft position sensor.
Unable to start engine

Fail-safe system
Unable to drive vehicle
Tool display —
Procedure —
8-87
Crankshaft position sensor: no normal signals are received from

Item
the crankshaft position sensor.
1 Connection of crankshaft posi- Improperly connected  Con- Crank the engine, and then
tion sensor coupler. nect the coupler securely or check the condition of the fault
Check the locking condition of replace the wire harness. code using the malfunction
item 2.
2 Connection of ECU coupler. Improperly connected  Con- Crank the engine, and then
Check the locking condition of nect the coupler securely or check the condition of the fault
the coupler. replace the wire harness. code using the malfunction
item 3.
3 Wire harness continuity. Open or short circuit  Replace Crank the engine, and then
the wire harness. check the condition of the fault
Between crankshaft position code using the malfunction
sensor coupler and ECU cou- mode of the Yamaha diagnostic
pler. tool.
black/yellow–black/yellow Condition is “Recovered”  Go
Between crankshaft position to item 7 and finish the service.
sensor coupler and joint con- Condition is “Detected”  Go to
nector. item 4.
black/blue–black/blue
Between joint connector and
ECU coupler.
4 Installed condition of crankshaft Improperly installed sensor  Crank the engine, and then
position sensor. Reinstall or replace the sensor. check the condition of the fault
Check for looseness or pinch- Refer to “GENERATOR AND code using the malfunction
ing. STARTER CLUTCH” on page mode of the Yamaha diagnostic
Check the gap between the 5-44. tool.
crankshaft position sensor and Condition is “Recovered”  Go
the generator rotor. to item 7 and finish the service.
item 5.
5 Defective crankshaft position Check the crankshaft position Crank the engine, and then
sensor. sensor. check the condition of the fault
Refer to “CHECKING THE code using the malfunction
CRANKSHAFT POSITION mode of the Yamaha diagnostic
SENSOR” on page 8-242. tool.
Replace if defective. Condition is “Recovered”  Go
item 6.
page 8-230.
code.
8-88

Ignition coil: open or short circuit detected in the primary lead of

Item
the ignition coil.

Fail-safe system
Actuates the ignition coil five times at one-second intervals.
each time the ignition coil is actuated.
Check that a spark is generated five times.
Procedure
• Connect an ignition checker.

1 Connection of ignition coil cou- Improperly connected  Con- Start the engine and let it idle for
pler. nect the coupler securely or approximately 5 seconds.
Check the locking condition of replace the wire harness. Check the condition of the fault
the coupler. code using the malfunction
item 2.
2 Connection of ECU coupler. Improperly connected  Con- Start the engine and let it idle for
Check the locking condition of nect the coupler securely or approximately 5 seconds.
the coupler. replace the wire harness. Check the condition of the fault
Disconnect the coupler and code using the malfunction
check the pins (bent or broken mode of the Yamaha diagnostic
terminals and locking condition tool.
of the pins). Condition is “Recovered”  Go
item 3.
3 Wire harness continuity. Open or short circuit  Replace Start the engine and let it idle for
the wire harness. approximately 5 seconds.
Between ignition coil coupler Check the condition of the fault
and ECU coupler. code using the malfunction
orange–orange mode of the Yamaha diagnostic
Between ignition coil coupler tool.
and diode switch coupler. Condition is “Recovered”  Go
red/black–red/black to item 7 and finish the service.
item 4.
4 Installed condition of ignition Check for looseness or pinch- Start the engine and let it idle for
coil. ing. approximately 5 seconds.
Improperly installed ignition coil Check the condition of the fault
 Reinstall or replace the igni- code using the malfunction
tion coil. mode of the Yamaha diagnostic
tool.
item 5.
8-89
Ignition coil: open or short circuit detected in the primary lead of

Item
the ignition coil.
5 Defective ignition coil. Measure the primary coil resis- Start the engine and let it idle for
tance of the ignition coil. approximately 5 seconds.
Replace if out of specification. Check the condition of the fault
Refer to “CHECKING THE code using the malfunction
IGNITION COIL” on page 8-241. mode of the Yamaha diagnostic
tool.
item 6.
6 Malfunction in ECU. Execute the diagnostic mode. Service is finished.
(Code No. 30)
No spark  Replace the ECU.
page 8-230.
code.

Rear wheel sensor: no normal signals are received from the rear
Item
wheel sensor.

Fail-safe system
Rear wheel speed pulse
Tool display
0–999
Check that the number increases when the rear wheel is rotated. The
Procedure
number is cumulative and does not reset each time the wheel is stopped.
1 Connection of rear wheel sen- Improperly connected  Con- Execute the diagnostic mode.
sor coupler. nect the coupler securely or (Code No. 07)
Check the locking condition of replace the wire harness. Rotate the rear wheel by hand
the coupler. and check that the indicated
Disconnect the coupler and value increases.
check the pins (bent or broken Value increases  Go to item 7.
terminals and locking condition Value does not increase  Go
of the pins). to item 2.
2 Connection of ABS ECU cou- Improperly connected  Con- Execute the diagnostic mode.
pler. nect the coupler securely or (Code No. 07)
Check the locking condition of replace the wire harness. Rotate the rear wheel by hand
check the pins (bent or broken Value increases  Go to item 7.
terminals and locking condition Value does not increase  Go
of the pins). to item 3.
8-90
Rear wheel sensor: no normal signals are received from the rear
Item wheel sensor.
the coupler. replace the wire harness. Rotate the rear wheel by hand
Disconnect the coupler and and check that the indicated
check the pins (bent or broken value increases.
terminals and locking condition Value increases  Go to item 7.
of the pins). Value does not increase  Go
to item 4.
4 Rear wheel sensor lead continu- Open or short circuit, or defec- Execute the diagnostic mode.
ity, or defective rear wheel sen- tive sensor  Replace the rear (Code No. 07)
sor. wheel sensor. Rotate the rear wheel by hand
Between rear wheel sensor cou- and check that the indicated
pler and ABS ECU coupler. value increases.
black–black Value increases  Go to item 7.
white–white Value does not increase  Go
Between ABS ECU coupler and to item 5.
ECU coupler.
white/green–white/green
5 Malfunction in ECU. Replace the ECU. Execute the diagnostic mode.
Refer to “REPLACING THE (Code No. 07)
ECU (Engine Control Unit)” on Rotate the rear wheel by hand
page 8-230. and check that the indicated
value increases.
Value increases  Go to item 7.
Value does not increase  Go
to item 6.
6 Malfunction in ABS ECU. Replace the ABS ECU. Go to item 7.
7 Delete the fault code and check Push the ON/start switch, and
that the engine trouble warning then rotate the rear wheel by
light goes off. hand.
Start the engine, and input the
vehicle speed signals by operat-
ing the vehicle at 20 to 30 km/h
(12 to 19 mph).
Confirm that the fault code has
Delete this fault code even if it
has a condition of “Detected”.
8-91

TIP
Item Engine idling speed is too high.

Fail-safe system
Tool display —
Procedure —
1 Intake system abnormal (intake Check the throttle bodies. Start the engine and let it idle for
of secondary air supply). Replace if defective. approximately 5 minutes.
Refer to “THROTTLE BODY” on Check the condition of the fault
page 7-5. code using the malfunction
tool.
item 2.
2 ISC learning overcompensated. Check the intake system and Start the engine and let it idle for
clean the throttle body. approximately 5 minutes.
Refer to “CHECKING AND Check the condition of the fault
CLEANING THE THROTTLE code using the malfunction
BODIES” on page 7-9. mode of the Yamaha diagnostic
Execute the diagnostic mode. tool.
(Code No. 67) Condition is “Recovered”  Go
Execute clearing of the ISC to item 4 and finish the service.
learning data. Condition is “Detected”  Go to
item 3.
page 8-230.
code.
8-92

Item Charging voltage is abnormal.

Fail-safe system
Tool display —
Procedure —
1 Malfunction in charging system. Check the charging system. Start the engine and let it idle for
Refer to “CHARGING SYSTEM” approximately 5 seconds.
on page 8-19. Check the condition of the fault
Defective rectifier/regulator or code using the malfunction
AC magneto  Replace. mode of the Yamaha diagnostic
Defective connection in the tool.
charging system circuit  Prop- Condition is “Recovered”  Go
erly connect or replace the wire to item 2 and finish the service.
harness. Condition is “Detected” 
Repeat item 1.
code.

Internal malfunction in ECU. (When this malfunction is detected in

Item the ECU, the fault code number might not appear on the tool dis-
play.)

Fail-safe system
Tool display —
Procedure —
1 Malfunction in ECU. Replace the ECU. Push the ON/start switch.
Refer to “REPLACING THE Check that the engine trouble
ECU (Engine Control Unit)” on warning light does not come on.
page 8-230.
8-93
Fault code No. P062F

EEPROM fault code number: an error is detected while reading or

Item
writing on EEPROM.

Fail-safe system
00
• No malfunctions detected (If the self-diagnosis fault code P062F is indi-
cated, the ECU is defective.)
01, 02 (CO adjustment value)
• (If more than one cylinder is defective, the display alternates every two
Tool display seconds to show all the detected cylinder numbers. When all cylinder
numbers are shown, the display repeats the same process.)
11 (Data error for ISC (idle speed control) learning values)
12 (O2 feedback learning value)
13 (OBD memory value)
Procedure —
1 Locate the malfunction. Execute the diagnostic mode.
(Code No. 60)
00: Go to item 5.
01: Go to item 2.
02: Go to item 3.
11–13: Go to item 4.
2 “01” is indicated in diagnostic Change the CO concentration of Push the ON/start switch, and
mode. (Code No. 60) cylinder #1, and rewrite in then check the condition of the
EEPROM data error for adjust- EEPROM. fault code using the malfunction
ment of CO concentration of cyl- Refer to “ADJUSTING THE mode of the Yamaha diagnostic
inder #1. EXHAUST GAS VOLUME” on tool.
page 3-12. Condition is “Recovered”  Go
After this adjustment is made, to item 6 and finish the service.
push the OFF/LOCK switch. Condition is “Detected” 
Repeat item 1.
If the same number is indicated,
go to item 5.
3 “02” is indicated in diagnostic Change the CO concentration of Push the ON/start switch, and
mode. (Code No. 60) cylinder #2, and rewrite in then check the condition of the
EEPROM data error for adjust- EEPROM. fault code using the malfunction
ment of CO concentration of cyl- Refer to “ADJUSTING THE mode of the Yamaha diagnostic
inder #2. EXHAUST GAS VOLUME” on tool.
page 3-12. Condition is “Recovered”  Go
After this adjustment is made, to item 6 and finish the service.
push the OFF/LOCK switch. Condition is “Detected” 
Repeat item 1.
If the same number is indicated,
go to item 5.
8-94
EEPROM fault code number: an error is detected while reading or

Item
writing on EEPROM.
4 “11” is indicated in diagnostic Push the OFF/LOCK switch. Push the ON/start switch, and
mode. (Code No. 60) then check the condition of the
EEPROM data error for ISC fault code using the malfunction
(idle speed control) learning val- mode of the Yamaha diagnostic
ues. tool.
“12” is indicated in the diagnos- Condition is “Recovered”  Go
tic mode. (Code No. 60) to item 6 and finish the service.
EEPROM data error for O2 feed- Condition is “Detected” 
back learning values. Repeat item 1.
“13” is indicated in the diagnos- If the same number is indicated,
tic mode. (Code No. 60) go to item 5.
EEPROM data error for OBD
memory values.
page 8-230.
code.

Item YCC-T drive system: malfunction detected.

Fail-safe system
Tool display —
Procedure —
1 Connection of throttle servo Improperly connected  Con- Push the ON/start switch, and
motor coupler. nect the coupler securely or then check the condition of the
item 2.
Disconnect the coupler and replace the wire harness. fault code using the malfunction
item 3.
8-95
Item YCC-T drive system: malfunction detected.
3 Check the electronic throttle Abnormality  Replace the Push the ON/start switch, and
valve fuse. electronic throttle valve fuse. then check the condition of the
tool.
item 4.
Between throttle servo motor fault code using the malfunction
coupler and ECU coupler. mode of the Yamaha diagnostic
yellow/red–yellow/red tool.
yellow/red–yellow/red Condition is “Recovered”  Go
Between ECU coupler and fuse to item 8 and finish the service.
box (electronic throttle valve Condition is “Detected”  Go to
fuse). item 5.
red/blue–red/blue
5 Defective throttle servo motor. Check the throttle servo motor. Push the ON/start switch, and
Replace the throttle bodies if then check the condition of the
defective. fault code using the malfunction
Refer to “CHECKING THE mode of the Yamaha diagnostic
THROTTLE SERVO MOTOR” tool.
on page 8-247. Condition is “Recovered”  Go
item 6.
6 Defective throttle bodies. Check the throttle bodies. Push the ON/start switch, and
Replace if defective. then check the condition of the
Refer to “CHECKING THE fault code using the malfunction
THROTTLE SERVO MOTOR” mode of the Yamaha diagnostic
on page 8-247. tool.
item 7.
ECU” on page 8-211.
code.
8-96

Fuel system voltage: incorrect voltage supplied to the fuel injector

Item
and fuel pump.

Fail-safe system
Fuel system voltage (battery voltage)
Tool display
Approximately 12.0
09 Set the engine stop switch to “ ”, and then compare the actually mea-
Procedure sured battery voltage with the tool display value. (If the actually mea-
sured battery voltage is low, recharge the battery.)
Actuates the starting circuit cut-off relay five times at one-second inter-
Actuation vals.
The “check” indicator on the Yamaha diagnostic tool screen come on
50 each time the relay is actuated.
Procedure Check that the starting circuit cut-off relay is actuated five times by listen-
ing for the operating sound.
1 Connection of fuel injection sys- Improperly connected  Con- Start the engine and let it idle for
tem relay coupler. nect the coupler securely or approximately 5 seconds.
item 2.
item 3.
8-97
Fuel system voltage: incorrect voltage supplied to the fuel injector

Item
and fuel pump.
Between starter relay and igni- Check the condition of the fault
tion system relay coupler. code using the malfunction
red–red mode of the Yamaha diagnostic
Between ignition system relay tool.
coupler and remote control unit Condition is “Recovered”  Go
coupler. to item 7 and finish the service.
yellow/blue–yellow/blue Condition is “Detected”  Go to
Between ignition system relay item 4.
coupler and ignition fuse.
brown/blue–brown/blue
Between ignition fuse and han-
dlebar switch (right) coupler.
red/white–red/white
Between handlebar switch
(right) coupler and fuel injection
system relay coupler.
red/black–red/black
Between starter relay and fuel
injection system fuse.
red–red
Between fuel injection system
fuse and fuel injection system
relay coupler.
red–red
Between fuel injection system
relay coupler and ECU coupler.
red/blue–red/blue
blue/yellow–blue/yellow
4 Defective fuel injection system Execute the diagnostic mode. Start the engine and let it idle for
relay. (Code No. 50) approximately 5 seconds.
No operating sound  Replace Check the condition of the fault
the fuel injection system relay code using the malfunction
and ignition system relay. mode of the Yamaha diagnostic
tool.
item 5.
5 Defective fuel injection system Execute the diagnostic mode. Start the engine and let it idle for
relay. (Code No. 09) approximately 5 seconds.
Fuel system voltage is below 3 Check the condition of the fault
V  Replace the fuel injection code using the malfunction
system relay and ignition sys- mode of the Yamaha diagnostic
tem relay. tool.
item 6.
page 8-230.
code.
8-98

Sidestand switch: open or short circuit of the light green lead of the
Item
ECU is detected.

Fail-safe system
Sidestand switch
Tool display • “ON” (sidestand retracted)
• “OFF” (sidestand extended)
Procedure Extend and retract the sidestand (with the transmission in gear).
1 Connection of sidestand switch Improperly connected  Con- Push the ON/start switch, and
coupler. nect the coupler securely or then extend and retract the side-
Check the locking condition of replace the wire harness. stand.
the coupler. Check the condition of the fault
item 2.
Check the locking condition of nect the coupler securely or then extend and retract the side-
the coupler. replace the wire harness. stand.
Disconnect the coupler and Check the condition of the fault
check the pins (bent or broken code using the malfunction
terminals and locking condition mode of the Yamaha diagnostic
of the pins). tool.
item 3.
3 Connection of sidestand switch Improperly connected  Con- Push the ON/start switch, and
coupler. nect the coupler securely or then extend and retract the side-
Check the locking condition of replace the wire harness. stand.
item 4.
the wire harness. then extend and retract the side-
Between sidestand switch cou- stand.
pler and ECU coupler. Check the condition of the fault
light green–light green code using the malfunction
Between sidestand switch cou- mode of the Yamaha diagnostic
pler and ground. tool.
black–black Condition is “Recovered”  Go
item 5.
8-99
Sidestand switch: open or short circuit of the light green lead of the
Item
ECU is detected.
5 Defective sidestand switch. Execute the diagnostic mode. Push the ON/start switch, and
(Code No. 20) then extend and retract the side-
Sidestand retracted: “ON” stand.
Sidestand extended: “OFF” Check the condition of the fault
Replace if defective. code using the malfunction
tool.
item 6.
page 8-230.
code.

Malfunction in ECU internal circuit (malfunction of ECU power cut-

Item off function).

Fail-safe system
Tool display —
Procedure —
1 Installed condition of battery Improperly installed battery or Push the ON/start switch, and
leads. battery leads  Reinstall or then check the condition of the
Check the installed condition of replace the battery leads. fault code using the malfunction
the battery and battery leads mode of the Yamaha diagnostic
(loose bolts). tool.
item 2.
2 Connection of starter relay cou- Improperly connected  Con- Push the ON/start switch, and
item 3.
8-100
Malfunction in ECU internal circuit (malfunction of ECU power cut-

Item
off function).
3 Check the main fuse. Blown fuse  Replace the fuse. Push the ON/start switch, and
tool.
item 4.
4 Wire harness continuity Open or short circuit  Replace Push the ON/start switch, and
between starter relay and ECU the wire harness. then check the condition of the
coupler. Between starter relay and ECU fault code using the malfunction
coupler. mode of the Yamaha diagnostic
red–red tool.
item 5.
5 Wire harness continuity Open or short circuit  Replace Push the ON/start switch, and
between starter relay and bat- the wire harness. then check the condition of the
tery. Between starter relay and bat- fault code using the malfunction
tery. mode of the Yamaha diagnostic
red–red tool.
item 6.
code.

[P1604] Lean angle sensor: ground short circuit detected.

Item
[P1605] Lean angle sensor: open or power short circuit.

Fail-safe system
Tool display • 0.4–1.4 (upright)
• 3.7–4.4 (overturned)
Procedure Remove the lean angle sensor and incline it more than 65 degrees.
8-101

Item
1 Connection of lean angle sensor Improperly connected  Con- Push the ON/start switch, then
coupler. nect the coupler securely or to “OFF”, and then back to
Check the locking condition of replace the wire harness. “ON”.
item 2.
2 Connection of ECU coupler. Improperly connected  Con- Push the ON/start switch, then
Check the locking condition of nect the coupler securely or to “OFF”, and then back to
the coupler. replace the wire harness. “ON”.
Disconnect the coupler and Check the condition of the fault
check the pins (bent or broken code using the malfunction
terminals and locking condition mode of the Yamaha diagnostic
of the pins). tool.
item 3.
3 Wire harness continuity. Open or short circuit  Replace Push the ON/start switch, then
the wire harness. to “OFF”, and then back to
“ON”.
Check the condition of the fault
code using the malfunction
tool.
item 4.
3-1
2
1 5V 5V
L
3 L
Y/G
4 Y/G
B/L
5 B/L
1. Lean angle sensor

2. ECU
Disconnect the lean angle sensor coupler from the lean angle sensor.
8-102

Item

Between lean angle sensor coupler and ground: yellow/green–ground

Between lean angle sensor coupler and ECU coupler: blue–blue
O B R/B G Y/W Y/R R/L R R/W O B R/B G Y/W Y/R R/L R R/W O B R/B G Y/W Y/R R/L R R/W
Y/W B G/B B Y/W B G/B B Y/W B G/B B
Y/R L/Y G L B/W Y/R L/Y G L B/W Y/R L/Y G L B/W
A. XP530E-A
B. XP530-A
C. XP530D-A
Between lean angle sensor coupler and ECU coupler: yellow/green–yellow/green
A. XP530E-A
B. XP530-A
C. XP530D-A
8-103

Item

Between lean angle sensor coupler and ECU coupler: black/blue–black/blue
A. XP530E-A
B. XP530-A
C. XP530D-A
Between lean angle sensor output terminal (yellow/green) “a” of ECU coupler and any other ECU
B/L B/W P/W L L a B/L B/W W/G P/W L L a B/L B/W W/G Lg/L P/W L L a
b b b
A. XP530E-A
B. XP530-A
C. XP530D-A
4 Defective lean angle sensor. Refer to “CHECKING THE Push the ON/start switch, then
LEAN ANGLE SENSOR” on to “OFF”, and then back to
page 8-242. “ON”.
Check the condition of the fault
tool.
item 5.
page 8-230.
8-104

Item [P1605] Lean angle sensor: open or power short circuit.
code.

TIP
If a fault code other than No. “P2138” (“P2122, P2123, P2127, P2128”) is detected, perform trouble-
shooting first.
[P2122] Accelerator position sensor: open or ground short circuit

detected.
[P2123] Accelerator position sensor: power short circuit detected.
Item [P2127] Accelerator position sensor: ground short circuit detected.
[P2128] Accelerator position sensor: open or power short circuit
detected.
[P2138] Accelerator position sensor: output voltage deviation error.

Fail-safe system
Accelerator position sensor signal 1
• Check with throttle grip in fully closed position.
Procedure • Check with throttle grip in fully open position.
Accelerator position sensor signal 2
Procedure • Check with throttle grip in fully closed position.

• Check with throttle grip in fully open position.
1 Connection of accelerator posi- Improperly connected  Con- Push the ON/start switch, and
tion sensor coupler. nect the coupler securely or then check the condition of the
item 2.
item 3.
8-105

detected.
detected.
tool.
item 4.
3-1
2
1 5V
L
3 L
W
4 W
5V
R
5 R
B/L
6 B/L

2. ECU
Disconnect the accelerator position sensor coupler from the accelerator position sensor.
8-106

detected.
detected.

Between accelerator position sensor coupler and ground: white–ground

Between accelerator position sensor coupler and ECU coupler: white–white
R R R
A. XP530E-A
B. XP530-A
C. XP530D-A
Between accelerator position sensor coupler and ground: red–ground
8-107

detected.
detected.

Between accelerator position sensor coupler and ECU coupler: red–red
R R R
A. XP530E-A
B. XP530-A
C. XP530D-A
Between accelerator position sensor coupler and ECU coupler: blue–blue
R R R
A. XP530E-A
B. XP530-A
C. XP530D-A
8-108

detected.
detected.

Between accelerator position sensor coupler and ECU coupler: black/blue–black/blue
R R R
A. XP530E-A
B. XP530-A
C. XP530D-A
Between accelerator position sensor output terminal (white) “a” of ECU coupler and any other ECU
a a a
b b b
A. XP530E-A
B. XP530-A
C. XP530D-A
8-109

detected.
detected.

Between accelerator position sensor output terminal (red) “a” of ECU coupler and any other ECU
a a a
b b b
A. XP530E-A
B. XP530-A
C. XP530D-A
4 Installed condition of accelera- Check for looseness or pinch- Push the ON/start switch, and
tor position sensor. ing. then check the condition of the
Reinstall or adjust the sensor. mode of the Yamaha diagnostic
Refer to “ADJUSTING THE tool.
THROTTLE POSITION SEN- Condition is “Recovered”  Go
SOR” on page 7-13. to item 7 and finish the service.
item 5.
5 Defective accelerator position Check accelerator position sen- Push the ON/start switch, and
sensor. sor signal 1. then check the condition of the
Execute the diagnostic mode. fault code using the malfunction
(Code No. 14) mode of the Yamaha diagnostic
When the throttle grip is fully tool.
closed: Condition is “Recovered”  Go
A value of 11–20 is indicated. to item 7 and finish the service.
When the throttle grip is fully Condition is “Detected”  Go to
open: item 6.
Check accelerator position sen-

sor signal 2.
(Code No. 15)
When the throttle grip is fully
closed:
When the throttle grip is fully
open:
An indicated value is out of the

specified range  Replace the
accelerator position sensor.
8-110

detected.
detected.

page 8-230.
code.

Item Front wheel sensor: no normal signals are received from the front
wheel sensor.

Fail-safe system
Tool display Front wheel speed pulse

0–999
Check that the number increases when the front wheel is rotated. The
Procedure
number is cumulative and does not reset each time the wheel is stopped.
1 Connection of front wheel sen- Improperly connected  Con- Execute the diagnostic mode.
sor coupler. nect the coupler securely or (Code No. 16)
Check the locking condition of replace the wire harness. Rotate the front wheel by hand
check the pins (bent or broken Value increases  Go to item 7
terminals and locking condition and finish the service.
to item 2.
2 Connection of ABS ECU cou- Improperly connected  Con- Execute the diagnostic mode.
pler. nect the coupler securely or (Code No. 16)
Check the locking condition of replace the wire harness. Rotate the front wheel by hand
check the pins (bent or broken Value increases  Go to item 7
terminals and locking condition and finish the service.
to item 3.
8-111
Front wheel sensor: no normal signals are received from the front
Item
wheel sensor.
the coupler. replace the wire harness. Rotate the front wheel by hand
Disconnect the coupler and and check that the indicated
check the pins (bent or broken value increases.
terminals and locking condition Value increases  Go to item 7
of the pins). and finish the service.
to item 4.
Between front wheel sensor Rotate the front wheel by hand
coupler and ABS ECU coupler. and check that the indicated
black–black value increases.
white–white Value increases  Go to item 7
Between ABS ECU coupler and and finish the service.
ECU coupler. Value does not increase  Go
white/yellow–white/yellow to item 5.
5 Malfunction in ECU. Replace the ECU. Execute the diagnostic mode.
Refer to “REPLACING THE (Code No. 16)
ECU (Engine Control Unit)” on Rotate the front wheel by hand
page 8-230. and check that the indicated
value increases.
Value increases  Go to item 7
and finish the service.
to item 6.
6 Malfunction in ABS ECU. Replace the ABS ECU. Go to item 7.
7 Delete the fault code and check Push the ON/start switch, and
that the engine trouble warning then rotate the front wheel by
light goes off. hand.
Start the engine, and input the
vehicle speed signals by operat-
ing the vehicle at 20 to 30 km/h
(12 to 19 mph).
Confirm that the fault code has
Delete this fault code even if it
has a condition of “Detected”.
8-112

TIP
If fault code numbers “P0657”, “P2195” and “P0030”, two or more numbers are indicated, take the ac-
tions specified for fault code number “P0657”, “P0030” and “P2195” in the order.
Item O2 sensor: open circuit detected.

Fail-safe system
Tool display —
Procedure —
1 Installed condition of O2 sensor. Check for looseness or pinch- Start the engine and let it idle for
ing. approximately 10 seconds.
Improperly installed sensor  Check the condition of the fault
Reinstall or replace the sensor. code using the malfunction
tool.
item 2.
Also, delete this fault code,
which has a condition of
“Detected”.
2 Connection of O2 sensor cou- Improperly connected  Con- Start the engine and let it idle for
pler. nect the coupler securely or approximately 10 seconds.
item 3.
“Detected”.
item 4.
“Detected”.
8-113
Item O2 sensor: open circuit detected.
Between O2 sensor coupler and Check the condition of the fault
ECU coupler. code using the malfunction
gray/green–gray/green mode of the Yamaha diagnostic
pink/black–pink/black tool.
Between O2 sensor coupler and Condition is “Recovered”  Go
joint connector. to item 8 and finish the service.
black/blue–black/blue Condition is “Detected”  Go to
Between O2 sensor coupler and item 5.
ECU coupler. which has a condition of
black–black “Detected”.
Between O2 sensor coupler and
joint coupler.
red/blue–red/blue
Between joint connector and
ECU coupler.
Between O2 sensor and fuel
injection system relay.
red/blue–red/blue
5 Check fuel pressure. Refer to “CHECKING THE Start the engine and let it idle for
FUEL PRESSURE” on page approximately 10 seconds.
7-12. Check the condition of the fault
tool.
item 6.
“Detected”.
6 Defective O2 sensor. Check the O2 sensor. Start the engine and let it idle for
Replace if defective. approximately 10 seconds.
Refer to “ENGINE REMOVAL” Check the condition of the fault
on page 5-2. code using the malfunction
tool.
item 7.
“Detected”.
page 8-230.
code.
8-114
Fault code No. U0155 or “Err”

TIP
“Err” is displayed on the clock display of the multi-function meter, but the engine trouble warning light
does not come on.
Fault code No. U0155 or “Err”
Multi-function meter: signals cannot be transmitted between the

Item
ECU and the multi-function meter.

1 Connection of meter assembly Improperly connected  Con- Push the ON/start switch, and
coupler. nect the coupler securely or then check the condition of the
item 2.
item 3.
Between meter assembly cou- fault code using the malfunction
pler and joint coupler. mode of the Yamaha diagnostic
light green/blue–light green/blue tool.
light green/white–light Condition is “Recovered”  Go
green/white to item 6 and finish the service.
Between joint coupler and ECU Condition is “Detected”  Go to
coupler. item 4.
light green/blue–light green/blue
light green/white–light
green/white
4 Defective meter assembly. Replace the meter assembly. Push the ON/start switch, and
tool.
item 5.
page 8-230.
code.
8-115
8-116
CRUISE CONTROL SYSTEM (for XP530D-A)
EAS20087

EAS30544
CIRCUIT DIAGRAM
8-117
4. Joint coupler
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
25.Backup fuse
41.Cruise control fuse
59.Cruise control power switch
60.Cruise control setting switch
63.Menu switch
64.Select switch
75.Brake light fuse
87.Meter assembly
95.Cruise control system indicator light
96.Cruise control setting indicator light
A. Wire harness
8-118
EAS30666
CRUISE CONTROL CIRCUIT OPERATION
8 9 10
11
17
12 13 14
6 7
15
16
3 19 18
2
20
1
8-119
1. Battery
2. Main fuse
3. Ignition system relay
4. Backup fuse
5. Fuel injection system fuse
6. Signaling system fuse
7. Brake light fuse
8. Ignition fuse
9. Cruise control system fuse
10.Cruise control power switch
11.Cruise control setting switch
18.Multi-function meter
19.Cruise control system indicator light
20.Cruise control setting indicator light
8-120
EAS30667
BASIC INSTRUCTIONS FOR TROUBLESHOOTING

EWA17420
WARNING
• Perform the troubleshooting [A][B][C] in order. Be sure to follow the order since a wrong
diagnosis could result if the steps are followed in a different order or omitted.
• Use sufficiently charged regular batteries only.
[A] Malfunction check using the cruise control system indicator light
[B] Use the Yamaha diagnostic tool to determine the cause of the malfunction for the stored fault code
from the condition and place where the malfunction occurred.
TIP
For information about using the Yamaha diagnostic tool, refer to “YAMAHA DIAGNOSTIC TOOL” on
page 8-62.
[C] Servicing the cruise control system
Execute the final check after disassembly and assembly.
8-121
EAS30668
BASIC PROCESS FOR TROUBLESHOOTING

[A] Push the cruise control Fails to come on • The cruise control power switch is
power switch, and check
defective.
the cruise control system
indicator light. Flashes
• The cruise control system fuse is
TIP blown.
Return to [A].
• If the engine trouble warning • The ECU is defective.
light is on, check the condition
of the fault code using the
malfunction mode of the
Refer to “TROUBLESHOOTING [B-1] Diagnosis using the fault
DETAILS (FAULT CODE)” [C-1] Delete the fault codes. Return to [A].
codes.
Comes on
[B-2] Check the malfunction

history using the malfunction Yes
mode of the Yamaha
diagnostic tool.
Is there any malfunction
history?
No
[B-3] Is there automatic Yes Explain the conditions for

deactivation history for the automatically deactivating the
cruise control system? cruise control system to the
customer.
No
OK
[C-2] Final check.
Fault code number is

not displayed.
Finished.
8-122
EWA17441
WARNING
When maintenance or checks have been performed on components related to the cruise control
system, be sure to perform a final check before delivering the vehicle to the customer.
Refer to “[C-2] FINAL CHECK” on page 8-133.
EAS30669
[A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR LIGHT

Push the ON/start switch, and then push the cruise control power switch.
1. The cruise control system indicator light does not come on.
• Check the control power switch for continuity. Refer to “CHECKING THE SWITCHES” on page
8-221. If there is no continuity, replace the handlebar switch (left).
• Check the fuse for continuity. Refer to “CHECKING THE FUSES” on page 8-229. If the cruise control
system fuse is blown, replace the fuse.
• Check for continuity between the orange/white terminal of the handlebar switch coupler (left) and
orange/white terminal of the ECU (engine control unit) coupler. If there is no continuity, the wire har-
ness is defective. Replace the wire harness.
2. The cruise control system indicator light flashes. [B-1]
3. The cruise control system indicator light come on. [B-2]
EAS30670
[B-1] DIAGNOSIS USING THE FAULT CODES

1. Information for the fault codes from the cruise control system is contained in the following table. Re-
fer to this table for troubleshooting.
Fault code table
Fault
Symptom Check point
code No.
P056C No normal signals from the switch are • Wire harness (ECU coupler and front or rear
received by the ECU. brake light switch coupler)
• Signaling system fuse and brake light fuses
• Connection of the brake light relay coupler
• Connection of the ignition system relay coupler
• Front brake light switch
• Rear brake light switch
P0564 No normal signals from the switch are • Wire harness (ECU coupler and handlebar
received by the ECU. switch coupler (left))
• Ignition fuse and cruise control system fuse
• Connection of the ignition system relay coupler
• Cruise control setting switch
Fault code No. P056C

A Front brake light switch: open or short circuit is detected.

Item
B Rear brake light switch: open or short circuit is detected.

Fail-safe system
“ON” (when the brakes are applied)
Tool display
“OFF” (when the brakes are not applied)
Procedure Operate the brake lever.

8-123

Item
A-1 Locate the malfunction. Execute the diagnostic mode.

(Code No. 82, 83)
When the front brake is applied: Malfunction  Go to item A-2.
“ON”
When the front brake is not
applied: “OFF”
When the rear brake is applied: Malfunction  Go to item B-2
“ON” for the rear brake light switch.
When the rear brake is not
applied: “OFF”
A-2 Connection of front brake light Improperly connected  Con- Push the ON/start switch.
switch coupler. nect the coupler securely or Operate the front brake lever,
Check the locking condition of replace the wire harness. and then check the condition of
the coupler. the fault code using the mal-
Disconnect the coupler and function mode of the Yamaha
check the pins (bent or broken diagnostic tool.
of the pins). to item A-10 and finish the ser-
vice.
item A-3.
A-3 Connection of brake light relay Improperly connected  Con- Push the ON/start switch.
coupler. nect the coupler securely or Operate the front brake lever,
vice.
item A-4.
A-4 Connection of ignition system Improperly connected  Con- Push the ON/start switch.
relay coupler. nect the coupler securely or Operate the front brake lever,
vice.
item A-5.
A-5 Connection of wire harness Improperly connected  Con- Push the ON/start switch.
ECU coupler. nect the coupler securely or Operate the front brake lever,
vice.
item A-6.
8-124

Item
A-6 Check the fuse. (signaling sys- Abnormality  Replace the Push the ON/start switch.
tem fuse, brake light fuse) fuse. (signaling system fuse, Operate the front brake lever,
brake light fuse) and then check the condition of
the fault code using the mal-
function mode of the Yamaha
diagnostic tool.
to item A-10 and finish the ser-
vice.
item A-7.
A-7 Wire harness continuity. Open or short circuit  Replace Push the ON/start switch.
the wire harness. Operate the front brake lever,
Between battery and ignition and then check the condition of
system relay coupler. the fault code using the mal-
red–red function mode of the Yamaha
Between ignition system relay diagnostic tool.
coupler and fuse box. Condition is “Recovered”  Go
brown/blue–brown/blue to item A-10 and finish the ser-
Between fuse box and front vice.
brake light switch. Condition is “Detected”  Go to
brown–green/white item A-8.
Between front brake light switch
coupler and brake light relay
coupler.
green/yellow–light green/black
Between brake light relay cou-
pler and ECU coupler.
light green/black–light
green/black
pler and battery.
black–black
A-8 Defective front brake light Replace the front brake light Push the ON/start switch.
switch. switch. Operate the front brake lever,
and then check the condition of
diagnostic tool.
vice.
item A-9.
A-9 Malfunction in ECU. Replace the ECU.
page 8-230.
A-10 Delete the fault code and check Confirm that the fault code has
code.
8-125

Item

Fail-safe system
“ON” (when the brakes are applied)
Tool display
“OFF” (when the brakes are not applied)
Procedure Operate the rear brake lever.
B-1 Locate the malfunction. Execute the diagnostic mode.
(Code No. 82, 83)
When the front brake is applied: Malfunction  Go to item A-2
“ON” for the front brake light switch.
When the front brake is not
applied: “OFF”
When the rear brake is applied: Malfunction  Go to item B-2.
“ON”
When the rear brake is not
applied: “OFF”
B-2 Connection of rear brake light Improperly connected  Con- Push the ON/start switch.
switch coupler. nect the coupler securely or Operate the rear brake lever,
of the pins). to item B-10 and finish the ser-
vice.
item B-3.
B-3 Connection of brake light relay Improperly connected  Con- Push the ON/start switch.
coupler. nect the coupler securely or Operate the rear brake lever,
vice.
item B-4.
B-4 Connection of ignition system Improperly connected  Con- Push the ON/start switch.
relay coupler. nect the coupler securely or Operate the rear brake lever,
vice.
item B-5.
8-126

Item
B-5 Connection of wire harness Improperly connected  Con- Push the ON/start switch.
ECU coupler. nect the coupler securely or Operate the rear brake lever,
vice.
item B-6.
B-6 Check the fuse. (signaling sys- Abnormality  Replace the Push the ON/start switch.
tem fuse, brake light fuse) fuse. (signaling system fuse, Operate the rear brake lever,
brake light fuse) and then check the condition of
diagnostic tool.
to item B-10 and finish the ser-
vice.
item B-7.
B-7 Wire harness continuity. Open or short circuit  Replace Push the ON/start switch.
the wire harness. Operate the rear brake lever,
Between ignition system relay and then check the condition of
coupler and fuse box. the fault code using the mal-
brown/blue–brown/blue function mode of the Yamaha
Between fuse box and rear diagnostic tool.
brake light switch. Condition is “Recovered”  Go
brown–green/yellow to item B-10 and finish the ser-
Between rear brake light switch vice.
coupler and brake light relay Condition is “Detected”  Go to
coupler. item B-8.
green/black
pler and ECU coupler.
green/black
pler and battery.
black–black
B-8 Defective rear brake light switch. Replace the rear brake light Push the ON/start switch.
switch. Operate the rear brake lever,
diagnostic tool.
vice.
item B-9.
B-9 Malfunction in ECU. Replace the ECU.
page 8-230.
8-127

Item
B-10 Delete the fault code and check Confirm that the fault code has
code.

Cruise control setting switch “RES+”: open or short circuit is

A detected.
Item
B Cruise
control setting switch “SET–”: open or short circuit is
detected.

Fail-safe system
“ON” (when the switch is pushed)
Tool display
“OFF” (when the switch is released)
Procedure Push and release the “RES+” side of the cruise control setting switch.
A-1 Locate the malfunction. Execute the diagnostic mode.
(Code No. 80)
When the cruise control setting Malfunction  Go to item A-2.
switch “RES+” is pushed: “ON”
When the cruise control setting
switch is released: “OFF”
(Code No. 81)
When the cruise control setting Malfunction  Go to item B-2
switch “SET–” is pushed: “ON” for the cruise control setting
When the cruise control setting switch “SET–”.
A-2 Connection of handlebar switch Improperly connected  Con- Push the ON/start switch.
coupler (left). nect the coupler securely or Push and release the “RES+”
Check the locking condition of replace the wire harness. side of the cruise control setting
the coupler. switch, and then check the con-
Disconnect the coupler and dition of the fault code using the
check the pins (bent or broken malfunction mode of the
terminals and locking condition Yamaha diagnostic tool.
vice.
item A-3.
8-128

A
detected.
Item
Cruise control setting switch “SET–”: open or short circuit is
B
detected.
A-3 Connection of ignition system Improperly connected  Con- Push the ON/start switch.
relay coupler. nect the coupler securely or Push and release the “RES+”
Check the locking condition of replace the wire harness. side of the cruise control setting
the coupler. switch, and then check the con-
Disconnect the coupler and dition of the fault code using the
check the pins (bent or broken malfunction mode of the
terminals and locking condition Yamaha diagnostic tool.
vice.
item A-4.
A-4 Connection of ECU coupler. Improperly connected  Con- Push the ON/start switch.
Check the locking condition of nect the coupler securely or Push and release the “RES+”
the coupler. replace the wire harness. side of the cruise control setting
Disconnect the coupler and switch, and then check the con-
check the pins (bent or broken dition of the fault code using the
terminals and locking condition malfunction mode of the
of the pins). Yamaha diagnostic tool.
vice.
item A-5.
A-5 Check the fuse. (ignition fuse, Abnormality  Replace the Push the ON/start switch.
cruise control system fuse) fuse. (ignition fuse, cruise con- Push and release the “RES+”
trol system fuse) side of the cruise control setting
switch, and then check the con-
dition of the fault code using the
malfunction mode of the
vice.
item A-6.
A-6 Wire harness continuity. Open or short circuit  Replace Push the ON/start switch.
the wire harness. Push and release the “RES+”
Between ignition system relay side of the cruise control setting
coupler and fuse box. switch, and then check the con-
brown/blue–brown/blue dition of the fault code using the
Between fuse box and handle- malfunction mode of the
bar switch coupler (left). Yamaha diagnostic tool.
red/white–yellow/black Condition is “Recovered”  Go
Between handlebar switch cou- to item A-9 and finish the ser-
pler (left) and ECU coupler. vice.
red/green–red/green Condition is “Detected”  Go to
item A-7.
8-129

A
detected.
Item
B Cruise control setting switch “SET–”: open or short circuit is
detected.
A-7 Defective cruise control setting Replace the handlebar switch Push the ON/start switch.
switch. (left). Push the “RES+” side and
“SET–” side of the cruise control
setting switch, and then check
the condition of the fault code
the Yamaha diagnostic tool.
vice.
item A-8.
A-8 Malfunction in ECU. Replace the ECU.
page 8-230.
A-9 Delete the fault code and check Confirm that the fault code has
code.
A Cruise
control setting switch “RES+”: open or short circuit is
detected.
Item
B Cruise control setting switch “SET–”: open or short circuit is
detected.

Fail-safe system
“ON” (when the switch is pushed)
Tool display
“OFF” (when the switch is released)
Procedure Push the “SET–” side of the cruise control setting switch.
B-1 Locate the malfunction. Execute the diagnostic mode.
(Code No. 80)
When the cruise control setting Malfunction  Go to item A-2
switch “RES+” is pushed: “ON” for the cruise control setting
When the cruise control setting switch “RES+”.
(Code No. 81)
When the cruise control setting Malfunction  Go to item B-2.
switch “SET–” is pushed: “ON”
When the cruise control setting
8-130

A
detected.
Item
B
detected.
B-2 Connection of handlebar switch Improperly connected  Con- Push the ON/start switch.
coupler (left). nect the coupler securely or Push and “SET–” side of the
Check the locking condition of replace the wire harness. cruise control setting switch,
the coupler. and then check the condition of
Disconnect the coupler and the fault code using the mal-
check the pins (bent or broken function mode of the Yamaha
terminals and locking condition diagnostic tool.
vice.
item B-3.
B-3 Connection of ignition system Improperly connected  Con- Push the ON/start switch.
relay coupler. nect the coupler securely or Push and “SET–” side of the
Check the locking condition of replace the wire harness. cruise control setting switch,
the coupler. and then check the condition of
Disconnect the coupler and the fault code using the mal-
check the pins (bent or broken function mode of the Yamaha
terminals and locking condition diagnostic tool.
vice.
item B-4.
B-4 Connection of ECU coupler. Improperly connected  Con- Push the ON/start switch.
Check the locking condition of nect the coupler securely or Push and “SET–” side of the
the coupler. replace the wire harness. cruise control setting switch,
Disconnect the coupler and and then check the condition of
check the pins (bent or broken the fault code using the mal-
terminals and locking condition function mode of the Yamaha
of the pins). diagnostic tool.
vice.
item B-5.
B-5 Check the fuse. (ignition fuse, Abnormality  Replace the Push the ON/start switch.
cruise control system fuse) fuse. (ignition fuse, cruise con- Push and “SET–” side of the
trol system fuse) cruise control setting switch,
diagnostic tool.
vice.
item B-6.
8-131

A
detected.
Item
B
detected.
B-6 Wire harness continuity. Open or short circuit  Replace Push the ON/start switch.
the wire harness. Push and “SET–” side of the
Between ignition system relay cruise control setting switch,
coupler and fuse box. and then check the condition of
brown/blue–brown/blue the fault code using the mal-
Between fuse box and handle- function mode of the Yamaha
bar switch coupler (left). diagnostic tool.
red/white–yellow/black Condition is “Recovered”  Go
Between handlebar switch cou- to item B-9 and finish the ser-
pler (left) and ECU coupler. vice.
green/blue–green/blue Condition is “Detected”  Go to
item B-7.
B-7 Defective cruise control setting Replace the handlebar switch Push the ON/start switch.
switch. (left). Push the “RES+” side and
“SET–” side of the cruise control
setting switch, and then check
the condition of the fault code
the Yamaha diagnostic tool.
vice.
item B-8.
B-8 Malfunction in ECU. Replace the ECU.
page 8-230.
B-9 Delete the fault code and check Confirm that the fault code has
code.
8-132
EAS30671
[B-2] DIAGNOSIS USING THE MALFUNCTION HISTORY CODES

Check the malfunction history using the malfunction mode of the Yamaha diagnostic tool.
• Malfunction history is displayed on the Yamaha diagnostic tool. [B-1]
• Malfunction history is not displayed on the Yamaha diagnostic tool. [B-3]
EAS31924
[B-3] MALFUNCTION HISTORY IS NOT DISPLAYED

Use the Yamaha diagnostic tool to check whether automatic deactivation history for the cruise control
system exists.
1. There is automatic deactivation history for the cruise control system.
• Explain the conditions for automatically deactivating the cruise control system to the customer.
• For information about the conditions for automatically deactivating the cruise control system.
Refer to “OUTLINE OF THE CRUISE CONTROL SYSTEM (for XP530D-A)” on page 1-4.
TIP
If you do not have a Yamaha diagnostic tool, the automatic deactivation history cannot be checked.
Therefore, explain the automatic deactivation function of the cruise control system to the customer and
explain that this is not a malfunction.
EAS30674
[C-1] DELETING THE FAULT CODES

1. Delete the fault code using the malfunction of the Yamaha diagnostic tool, and check that the engine
trouble warning light goes off.
EAS30675
[C-2] FINAL CHECK

1. Check the front brake lever and rear brake lever operation.
2. Check the rear brake light switches.
Refer to “CHECKING THE BRAKE LIGHT SWITCHES” on page 3-33.
3. Execute the diagnostic mode (code Nos. 82 and 83) to check the operation of the front brake light
switch, rear brake light switch, and grip cancel switch.
Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU)” on page 9-5.
4. Execute the diagnostic mode (code Nos. 80 and 81) to check the operation of the cruise control set-
ting switch.
5. Delete the fault codes.
6. Check the operation of the cruise control system.
Test ride the vehicle and confirm that the cruise control system is operating normally.
8-133
8-134
FUEL PUMP SYSTEM
EAS20081
FUEL PUMP SYSTEM

EAS30513
CIRCUIT DIAGRAM
XP530E-A
8-135
FUEL PUMP SYSTEM
4. Joint coupler
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
25.Backup fuse
106.Fuel pump
A. Wire harness
8-136
FUEL PUMP SYSTEM
XP530-A
8-137
FUEL PUMP SYSTEM
4. Joint coupler
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
25.Backup fuse
111.Fuel pump
A. Wire harness
8-138
FUEL PUMP SYSTEM
XP530D-A
8-139
FUEL PUMP SYSTEM
4. Joint coupler
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
25.Backup fuse
123.Fuel pump
A. Wire harness
8-140
FUEL PUMP SYSTEM
EAS30514
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
2. Storage box
3. Fuel tank
1. Check the fuses.

(Main, ignition, backup and fuel in-
jection system) Replace the fuse(s).
on page 8-229.
OK
page 8-230.
OK
3. Check the engine stop switch.
OK
OK
5. Check the fuel injection system re-
lay.
Replace the fuel injection system relay.
OK
6. Check the fuel pump.
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
PRESSURE” on page 7-12. NG
OK
7. Check the entire fuel pump sys-
tem’s wiring. Properly connect or replace the wire har-
page 8-135.
OK
Replace the ECU and/or remote con-
trol unit.
8-141
FUEL PUMP SYSTEM
8-142
WINDSHIELD DRIVE SYSTEM (for XP530D-A)
EAS20083

EAS30517
CIRCUIT DIAGRAM
8-143
3. Windshield motor fuse

4. Joint coupler
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
25.Backup fuse
63.Menu switch
64.Select switch
82.Windshield drive unit
83.Windshield drive unit relay (down)
84.Windshield drive unit relay (up)
87.Meter assembly
A. Wire harness
8-144
EAS30518
TROUBLESHOOTING
The windshield fails to move.
TIP
2. Leg shield
1. Check that there are no rocks or

other foreign material in the wind- Remove the foreign material.
shield drive unit side rails. NG
OK
2. Check that there is no foreign mate-
rial between the cable and the pul- Remove the foreign material.
ley. NG
OK
3. Check the fuses.
(Main, ignition, backup, and wind-
shield motor) Replace the fuse(s).
on page 8-229.
OK
page 8-230.
OK
Refer to “CHECKING THE Replace the ignition system relay.
OK
6. Check the menu switch.
• The menu switch is faulty.
NG • Replace the handlebar switch (left).
OK
7. Check the select switch.
• The select switch is faulty.
OK
8. Check the windshield drive unit re-
lay (up). Replace the windshield drive unit relay
Refer to “CHECKING THE RE- NG (up).
OK
8-145
9. Check the windshield drive unit re-

lay (down). Replace the windshield drive unit relay
Refer to “CHECKING THE RE- NG (down).
OK
10.Check the windshield drive motor.
Refer to “CHECKING THE WIND-
Replace the windshield drive unit.
SHIELD DRIVE UNIT (for XP530D- NG
A)” on page 8-247.
OK
11.Check the entire windshield drive
system wiring. Properly connect or replace the wire har-
page 8-143.
OK
8-146
GRIP WARMER SYSTEM (for XP530D-A)
EAS20167

EAS31007
CIRCUIT DIAGRAM
8-147
4. Joint coupler
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
25.Backup fuse
63.Menu switch
64.Select switch
87.Meter assembly
110.Grip warmer (left)
111.Grip warmer (right)
A. Wire harness
8-148
EAS31008
TROUBLESHOOTING
TIP
1. Front cowlings
2. Leg shield
3. Footboards
The grip warmers do not become warm at all.
1. Check that the engine trouble warn- Perform the troubleshooting for fault code
ing light is on and that “Err” is dis- No. U0155. Refer to “TROUBLESHOOT-
played in the multi-function meter NG ING DETAILS (FAULT CODE)” on page
display. 8-63.
OK
2. Check that the grip warmers are not Adjust the temperature levels of the grip
turned off. NG warmer settings.
OK
3. Check the fuses.
(Main, ignition, and backup)
on page 8-229.
OK
page 8-230.
OK
OK
6. Check that the engine is started. Start the engine.
NG
OK
7. Check the grip warmers.
Refer to “CHECKING THE GRIP
Replace the grip warmer(s).
WARMERS (for XP530D-A)” on NG
page 8-248.
OK
8. Check the entire grip warmer sys-
tem wiring. Properly connect or replace the wiring har-
page 8-147.
OK
8-149
9. Execute the diagnostic mode (code

Replace the ECU. Refer to “REPLACING
No. 57) to turn on the grip warmers,
THE ECU (Engine Control Unit)” on page
and then check that they become NG 8-230.
warm.
OK
The grip warmers are abnormally hot while the engine is idling.
1. Check that the temperature level of
Adjust the temperature levels of the grip
the low grip warmer setting is set to
NG warmer settings.
lowest temperature.
OK
Replace the ECU. Refer to “REPLAC-
ING THE ECU (Engine Control Unit)”
on page 8-230.
The grip warmers do not become very warm while the vehicle is traveling.
Adjust the temperature levels of the grip
the high grip warmer setting is set to
NG warmer settings.
highest temperature.
OK
2. Check that the engine trouble warn- Perform the troubleshooting for fault code
ing light is on and that fault code No. No. P0500. Refer to “TROUBLESHOOT-
P0500 is displayed in the Yamaha NG ING DETAILS (FAULT CODE)” on page
diagnostic tool display. 8-63.
OK
Replace the ECU. Refer to “REPLAC-
ING THE ECU (Engine Control Unit)”
on page 8-230.
The temperature levels of the grip warmer settings cannot be changed.

OK
OK
3. Check the wire harness between
Properly connect or replace the wiring har-
the handlebar switch (left) and the
NG ness.
meter assembly.
OK
8-150
SEAT HEATER SYSTEM (for XP530D-A)
EAS20312

EAS32438
CIRCUIT DIAGRAM
8-151
4. Joint coupler
15.Battery
17.Main fuse
19.Engine ground
25.Backup fuse
63.Menu switch
64.Select switch
87.Meter assembly
100.Seat heater relay (power)
101.Seat heater relay (control)
102.Seat heater
A. Wire harness
8-152
EAS32439
TROUBLESHOOTING
TIP
1. Front cowlings
2. Footboards
The seat heater do not become warm at all.
1. Check that the seat heater is not Adjust the temperature levels of the seat
turned off. NG heater settings.
OK
2. Check the fuses.
(Main, signaling system, and back-
up) Replace the fuse(s).
on page 8-229.
OK
3. Check that the engine is started. Start the engine.
NG
OK
page 8-230.
OK
OK
6. Check the seat heater relay (power).
Refer to “CHECKING THE RE- Replace the seat heater relay (power).
OK
7. Check the seat heater relay (con-
trol).
Replace the seat heater relay (control).
OK
8. Check the seat heater.
Refer to “CHECKING THE SEAT
Replace the seat heater.
HEATER (for XP530D-A)” on page NG
8-248.
OK
8-153
9. Check the entire seat heater system

wiring. Properly connect or replace the wiring har-
page 8-151.
OK
The seat heater is abnormally hot while the engine is idling.
Adjust the temperature levels of the seat
the low seat heater setting is set to
NG heater settings.
lowest temperature.
OK
OK
Replace the seat assembly.
8-248.
OK
The seat heater do not become very warm while the vehicle is traveling.
Adjust the temperature levels of the seat
the high seat heater setting is set to
NG heater settings.
highest temperature.
OK
OK
3. Check the seat heater relay (con-
trol).
Replace the seat heater relay (control).
OK
Replace the seat assembly.
8-248.
OK
8-154
The temperature levels of the seat heater settings cannot be changed.

OK
OK
3. Check the wire harness between
Properly connect or replace the wiring har-
the handlebar switch (left) and the
NG ness.
meter assembly.
OK
8-155
8-156
EAS20085

EAS30843
CIRCUIT DIAGRAM
XP530E-A
8-157
4. Joint coupler
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
25.Backup fuse
27.ABS motor fuse
29.ABS ECU fuse
75.Meter assembly
83.ABS warning light
108.Front wheel sensor
A. Wire harness
8-158
XP530-A
8-159
4. Joint coupler
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
25.Backup fuse
27.ABS motor fuse
29.ABS ECU fuse
77.Meter assembly
A. Wire harness
8-160
XP530D-A
8-161
4. Joint coupler
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
25.Backup fuse
27.ABS motor fuse
29.ABS ECU fuse
75.Brake light fuse
87.Meter assembly
A. Wire harness
8-162
EAS30525
ABS COMPONENTS CHART
2
4
3
1
10
9
8 7 6
8-163

2. ABS warning light
3. Fuse box (ABS motor fuse, ABS solenoid
fuse, and ABS ECU fuse)
4. ABS ECU
5. Front wheel sensor rotor
7. Front brake caliper
10.Rear wheel sensor rotor
8-164
EAS30844
ABS COUPLER LOCATION CHART
Dg P/W P/B Br/Y Ch Dg R/G R/W

Ch Dg Ch G/R G/L G W/G W/R W/L Y B/W Lg/W Lg/L B/W R/G R/G
(Gy)
Dg G/B P/W P/B B/W Br/Y L/R Br/Y Ch Dg R/G R/W

Ch Dg Ch G/R G/L G W/G W/R W/L Y B/W Lg/W Lg/L B/W R/G R/G
(Gy)
Dg G/B P/W P/B P/W P/B B/W Br/Y L/R Br/Y Ch Dg R/G R/W
Ch Dg Ch G/R G/L G W/G W/R W/L Y B/W Lg/WLg/L B/W R/G R/G
(Gy)
5
B W W Gy
Lg/L Lg/W
R/G B/W
7 6
R/W W B B W W/Y G/R G B
R/L G/Y G G Br/W Lg/L Lg/W B/L B/G W B W Gy
(B)
8-165
1. Rear wheel sensor coupler

2. Meter assembly coupler (for XP530E-A)
3. Meter assembly coupler (for XP530-A)
4. Meter assembly coupler (for XP530D-A)
6. Front wheel sensor coupler
7. ABS ECU coupler
8-166
EAS30845
MAINTENANCE OF THE ABS ECU

Checking the ABS ECU
1. Check:
• Terminals “1” of the ABS ECU
Cracks/damages  Replace the hydraulic unit assembly, brake hoses, and brake pipes that are
connected to the assembly as a set.
• Terminals “2” of the ABS ECU coupler
Connection defective, contaminated, come-off  Correct or clean.
TIP
If the ABS ECU coupler is clogged with mud or dirt, clean with compressed air.
1
2
EAS30528
ABS TROUBLESHOOTING OUTLINE

This section describes the troubleshooting for the ABS in detail. Read this service manual carefully and
make sure you fully understand the information provided before repairing any malfunctions or perform-
ing service.
The ABS ECU has a self-diagnosis function. When failures occur in the system, the ABS warning light
on the meter assembly indicates a malfunction.
The following troubleshooting describes the problem identification and service method using the
Yamaha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to “[B-2] DIAG-
NOSIS USING THE FAULT CODES” on page 8-171. For troubleshooting items other than the following
items, follow the normal service method.
EWA16710
WARNING
When maintenance or checks have been performed on components related to the ABS, be sure
to perform a final check before delivering the vehicle to the customer.
TIP
To final check, refer to “[C-1] FINAL CHECK” on page 8-191.
ABS operation when the ABS warning light comes on
1. The ABS warning light remains on  ABS operates as a normal brake system.
• A malfunction was detected using the ABS self-diagnosis function.
• The ABS self-diagnosis has not been completed.
The ABS self-diagnosis starts when the ON/start switch is pushed and finishes when the vehicle has
traveled at a speed of approximately 10 km/h (6 mi/h).
2. The ABS warning light comes on after the engine starts, and then goes off when the vehicle starts
moving (traveling at a speed of approximately 10 km/h (6 mi/h))  ABS operation is normal.
3. The ABS warning light flashes  ABS operation is normal.
• Refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 8-168.
8-167
Self-diagnosis and servicing

The ABS ECU has a self-diagnosis function. By utilizing this function, quick problem identification and
service are possible. Previous malfunctions can be checked since the ABS ECU also stores the mal-
function history.
The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the
service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in-
formation about deleting the fault codes, refer to “[B-3] DELETING THE FAULT CODES” on page
8-191. By deleting the fault codes stored in the ABS ECU memory, it is possible to pursue the cause
correctly if another malfunction occurs.
TIP
The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the
ON/start switch was pushed. During this test, a “clicking” noise can be heard from front side of the ve-
hicle, and if the front brake lever and rear brake lever are even slightly applied, a vibration can be felt
at the levers, but these do not indicate a malfunction.
Self-diagnosis using the ABS ECU

The ABS ECU performs a static check of the entire system when the ON/start switch is pushed. It also
checks for malfunctions while the vehicle is ridden. Since all malfunctions are recorded after they are
detected, it is possible to check the recorded malfunction data by utilizing the Yamaha diagnostic tool when
the ABS ECU has entered the self-diagnosis mode.
Special precautions for handling and servicing a vehicle equipped with ABS
ECA18490
NOTICE
Care should be taken not to damage components by subjecting them to shocks or pulling on
them with too much force since the ABS components are precisely adjusted.
• The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled.
• The malfunction history is stored in the memory of the ABS ECU. Delete the fault codes when the ser-
vice is finished. (This is because the past fault codes will be displayed again if another malfunction
occurs.)
EAS30529
BASIC INSTRUCTIONS FOR TROUBLESHOOTING

EWA17420
WARNING
• Perform the troubleshooting [A][B][C] in order. Be sure to follow the order since a wrong
diagnosis could result if the steps are followed in a different order or omitted.
• Use sufficiently charged regular batteries only.
[A] Malfunction check using the ABS warning light
[B] Use the Yamaha diagnostic tool and determine the location of the malfunction and the cause from
the recorded fault code.
Determine the cause of the malfunction from the condition and place where the malfunction occurred.
[C] Servicing the ABS
Execute the final check after disassembly and assembly.
8-168
EAS30530
BASIC PROCESS FOR TROUBLESHOOTING
[A] Push the ON/start switch Fails to • The ABS warning light (LED)
come on [A-1] Does only the ABS
and check the ABS warning Yes is defective.
warning light fail to Return to [A].
light. • The wire harness is grounded
come on?
between the ABS ECU and the
Comes on meter assembly.
• The meter assembly circuit is
defective.
• The hydraulic unit assembly is
defective.
No
• The ON/start switch is
[A-2] Do all indicator lights Yes defective. Return to [A].
fail to come on? • The battery voltage is low.
• The main fuse is blown.
• The meter assembly circuit is
defective.
Cannot
[A-3] The ABS warning light comes communicate [A-4] Only the ABS ECU Yes
• The ABS ECU fuse is blown.
on. • The ABS ECU coupler is Return to [A].
fails to communicate.
Connect the Yamaha disconnected.
diagnostic tool, and then
• The wire harness is defective.
execute functional diagnosis.
Can the tool communicate with • The hydraulic unit assembly
the ABS ECU? is defective.
No
Can communicate
[A-5] ABS ECU and FI ECU Yes • The connection with the Yamaha
Return to [A].
fail to communicate. diagnostic tool is defective.
• The wire harness is defective.
[B-1] Check for ABS fault Yes [B-2] Diagnose by the fault [B-3] Delete the fault codes.
Return to [A].
codes in the screen for the code.
Execute fault diagnosis.
Are fault codes displayed on
the screen?
The reaction force generated
No during brake line routing
confirmation is incorrect.
• The brake hoses and brake
[C-1] Perform the final checks. No pipes are not connected
Were all of the final checks correctly. Return to [A].
completed normally? The ABS warning light does
not go off when the light is
Yes checked.
(The ABS warning light • The malfunction is not
goes off when the light is
corrected.
checked.)
• There is a break in the wire
harness between the ABS ECU
and the meter assembly.
• The meter assembly circuit
is defective.
• The ABS warning light circuit
in the hydraulic unit assembly
is defective.
Finished.
8-169
EWA16710
WARNING
When maintenance or checks have been performed on components related to the ABS, be sure
to perform a final check before delivering the vehicle to the customer.
TIP
To final check, refer to “[C-1] FINAL CHECK” on page 8-191.
EAS30531
[A] CHECKING THE ABS WARNING LIGHT

Push the ON/start switch. (Do not start the engine.)
1. The ABS warning light does not come on.
• Only the ABS warning light fails to come on. [A-1]
• The ABS warning light and all other indicator lights fail to come on. [A-2]
2. The ABS warning light comes on. [A-3]
EAS30532
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON

1. Check for a short circuit to the ground between the green/red terminal of the ABS ECU coupler and
green/red terminal of the meter assembly.
• If there is short circuit to the ground, the wire harness is defective. Replace the wire harness.
2. Disconnect the ABS ECU coupler and check that the ABS warning light comes on when the ON/start
switch is pushed.
• If the ABS warning light does not come on, the meter assembly circuit (including the ABS warning
light [LED]) is defective. Replace the meter assembly.
• If the ABS warning light comes on, the ABS ECU is defective. Replace the hydraulic unit assembly.
EAS30964
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON

1. ON/start switch
• Check the ON/start switch for continuity.
Refer to “CHECKING THE SWITCHES” on page 8-221.
• If there is no continuity, replace the handlebar switch (right).
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-230.
• If the battery is defective, clean the battery terminals and recharge it, or replace the battery.
3. Main fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSES” on page 8-229.
• If the main fuse is blown, replace the fuse.
4. Circuit
• Check the meter assembly circuit.
Refer to “CIRCUIT DIAGRAM” on page 8-157.
• If the meter assembly circuit is open, replace the wire harness.
EAS31162
[A-3] THE ABS WARNING LIGHT COMES ON

Connect the Yamaha diagnostic tool to the Yamaha diagnostic tool coupler and execute functional di-
agnosis. (For information about how to execute functional diagnosis, refer to the operation manual that
is included with the tool.)
Check that communication with the ABS ECU is possible.
• Only the ABS ECU fails to communicate. [A-4]
• ABS ECU and FI ECU fail to communicate. [A-5]
• Communication is possible with the ABS ECU. [B-1] (The ABS is displayed on the select unit screen.)
8-170
EAS31163
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE (The select unit screen does not appear.)
1. ABS ECU fuse
• Check the ABS ECU fuse for continuity.
• If the ABS ECU fuse is blown, replace the fuse.
2. ABS ECU coupler
• Check that the ABS ECU coupler is connected properly.
For information about connecting the ABS ECU coupler properly, refer to “INSTALLING THE HY-
DRAULIC UNIT ASSEMBLY” on page 4-74.
3. Wire harness
• Open circuit between the battery and the ABS ECU, or between the ABS ECU and the ground.
Check for continuity between positive battery terminal and brown/white terminal of the ABS ECU
coupler.
Check for continuity between black/green terminal of the ABS ECU coupler and the ground, and be-
tween the black terminal of the ABS ECU coupler and ground.
If there is no continuity, the wire harness is defective. Replace the wire harness.
• Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou-
pler.
Check for continuity between blue/red terminal of the ABS ECU coupler and blue/red terminal of the
Yamaha diagnostic tool coupler. (CANH)
Check for continuity between blue/black terminal of the ABS ECU coupler and blue/black terminal
of the Yamaha diagnostic tool coupler. (CANL)
4. ABS ECU malfunction
Replace the hydraulic unit assembly.
EAS31164
[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE

1. Yamaha diagnostic tool
Check that the Yamaha diagnostic tool is properly connected.
2. Wire harness
• Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou-
pler.
Check for continuity between blue/red terminal of the ABS ECU coupler and blue/red terminal of the
Yamaha diagnostic tool coupler. (CANH)
Check for continuity between blue/black terminal of the ABS ECU coupler and blue/black terminal
of the Yamaha diagnostic tool coupler. (CANL)
EAS31165
[B-1] MALFUNCTION ARE CURRENTLY DETECTED

When the Yamaha diagnostic tool is connected to the Yamaha diagnostic tool coupler, the fault codes
will be displayed on the computer screen.
• A fault code is displayed. [B-2]
• A fault code is not displayed. [C-1]
EAS31166
[B-2] DIAGNOSIS USING THE FAULT CODES

This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is included
with the tool.
90890-03256
90890-03254
8-171

Removing the battery cover. Refer to “REMOVING THE BATTERY COVER” on page 4-10.
Removing the protective cap, and then connect the Yamaha diagnostic tool to the coupler “1”.
Details about the displayed fault codes are shown in the following chart. Refer to this chart and check
the vehicle.
Once all the work is complete, delete the fault codes. [B-3]
TIP
Check the inspection points after terminating the connection with the Yamaha diagnostic tool and
pressing the OFF/LOCK switch.
Fault code table
TIP
Record all of the fault codes displayed and inspect the check points.
Fault code
Item Symptom Check point
No.
11* Front wheel sensor (intermit- Front wheel sensor signal is • Foreign material adhered
25* tent pulses or no pulses) not received properly. around the front wheel sen-
(Pulses are not received or sor
are received intermittently • Incorrect installation of the
while the vehicle is traveling.) front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
12 Rear wheel sensor (intermit- Rear wheel sensor signal is • Foreign material adhered
tent pulses or no pulses) not received properly. around the rear wheel sen-
(Pulses are not received or sor
are received intermittently • Incorrect installation of the
while the vehicle is traveling.) rear wheel
rotor
• Defective rear wheel sen-
of the sensor
13* Front wheel sensor (abnor- Front wheel sensor signal is • Foreign material adhered
26* mal pulse period) not received properly. (The around the front wheel sen-
pulse period is abnormal sor
while the vehicle is traveling.) • Incorrect installation of the
front wheel
rotor
of the sensor
8-172
Fault code
No.
14* Rear wheel sensor (abnor- Rear wheel sensor signal is • Foreign material adhered
27* mal pulse period) not received properly. (The around the rear wheel sen-
pulse period is abnormal sor
while the vehicle is traveling.) • Incorrect installation of the
rear wheel
rotor
of the sensor
15 Front wheel sensor (open or Open or short circuit is • Defective coupler between
short circuit) detected in the front wheel the front wheel sensor and
sensor. the hydraulic unit assembly
• Open or short circuit in the
wire harness between the
front wheel sensor and the
hydraulic unit assembly
sor or hydraulic unit
assembly
16 Rear wheel sensor (open or Open or short circuit is • Defective coupler between
short circuit) detected in the rear wheel the rear wheel sensor and
sensor. the hydraulic unit assembly
rear wheel sensor and the
sor or hydraulic unit
assembly
17* Front wheel sensor (missing Front wheel sensor signal is • Foreign material adhered
45* pulses) not received properly. (Miss- around the front wheel sen-
ing pulses are detected in sor
the signal while the vehicle is • Incorrect installation of the
traveling.) front wheel
rotor
of the sensor
18* Rear wheel sensor (missing Rear wheel sensor signal is • Foreign material adhered
46* pulses) not received properly. (Miss- around the rear wheel sen-
traveling.) rear wheel
rotor
of the sensor
21 Hydraulic unit assembly Solenoid drive circuit in the • Defective hydraulic unit
(defective solenoid drive cir- hydraulic unit assembly is assembly
cuit) open or short-circuited.
8-173
Fault code
No.
24 Brake light switch or Brake light signal is not • Defective signaling system
tail/brake light received properly while the (tail/brake light or brake
vehicle is traveling. (Brake light switch)
light circuit, or front or rear • Defective coupler between
brake light switch circuit.) the signaling system
(tail/brake light or brake
light switch) and the
signaling system (tail/brake
light or brake light switch)
and the hydraulic unit
assembly
• Defective hydraulic unit
assembly
31 Hydraulic unit assembly Power is not supplied to the • Blown ABS solenoid fuse
(abnormal ABS solenoid solenoid circuit in the • Defective coupler between
power supply) hydraulic unit assembly. the battery and the hydrau-
lic unit assembly
battery and the hydraulic
unit assembly
assembly
32 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit
(short circuit in ABS solenoid the solenoid power supply assembly
power supply circuit) circuit in the hydraulic unit
assembly.
33 Hydraulic unit assembly Power is not supplied to the • Blown ABS motor fuse
(abnormal ABS motor power motor circuit in the hydraulic • Defective coupler between
supply) unit assembly. the battery and the hydrau-
lic unit assembly
unit assembly
assembly
34 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit
(short circuit in ABS motor the motor power supply cir- assembly
power supply circuit) cuit in the hydraulic unit
assembly.
41 Front wheel ABS (intermit- • Pulses from the front wheel • Incorrect installation of the
tent wheel speed pulses or sensor are received inter- front wheel sensor
incorrect depressurization) mittently while the vehicle • Incorrect rotation of the
is traveling. front wheel
• Front wheel will not recover • Front brake dragging
from the locking tendency • Defective hydraulic unit
even though the signal is assembly
transmitted from the ABS
ECU to reduce the hydrau-
lic pressure.
8-174
Fault code
No.
42 Rear wheel ABS (intermit- • Pulses from the rear wheel • Incorrect installation of the
47 tent wheel speed pulses or sensor are received inter- rear wheel sensor (for fault
incorrect depressurization) mittently while the vehicle code No. 42)
is traveling. (for fault code • Incorrect rotation of the
No. 42) rear wheel
• Rear wheel will not recover • Rear brake dragging
from the locking tendency • Defective hydraulic unit
even though the signal is assembly
transmitted from the ABS
ECU to reduce the hydrau-
lic pressure.
43 Front wheel sensor (missing Front wheel sensor signal is • Foreign material adhered
pulses) not received properly. (Miss- around the front wheel sen-
traveling.) front wheel
rotor
of the sensor
44 Rear wheel sensor (missing Rear wheel sensor signal is • Foreign material adhered
pulses) not received properly. (Miss- around the rear wheel sen-
traveling.) rear wheel
rotor
of the sensor
51 • Vehicle system power sup- • Power voltage supplied to • Defective battery
52 ply (voltage of ABS ECU the ABS ECU in the • Disconnected battery ter-
power supply is high) (for hydraulic unit assembly is minal
fault code No. 51) too high. (for fault code No. • Defective charging system
• Vehicle system power sup- 51)
ply (voltage of wheel sen- • Power voltage supplied to
sor power supply is high) the wheel sensor is too
(for fault code No. 52) high. (for fault code No. 52)
53 Vehicle system power supply Power voltage supplied to • Defective battery
(voltage of ABS ECU power the ABS ECU in the hydrau- • Defective coupler between
supply is low) lic unit assembly is too low. the battery and the hydrau-
lic unit assembly
unit assembly
• Defective charging system
54 Hydraulic unit assembly Abnormality is detected in • Defective battery
(defective ABS solenoid and the solenoid or motor power • Defective coupler between
ABS motor power supply cir- supply circuit in the hydraulic the battery and the hydrau-
cuits) unit assembly. lic unit assembly
unit assembly
• Defective charging system
assembly
8-175
Fault code Item Symptom Check point

No.
55 Hydraulic unit assembly Abnormal data is detected in • Defective hydraulic unit

(defective ABS ECU) the hydraulic unit assembly. assembly
56 Hydraulic unit assembly Abnormality is detected in • Defective hydraulic unit
(abnormal internal power the power supply circuit in assembly
supply) the hydraulic unit assembly.
63 Front wheel sensor power Power voltage supplied from • Short circuit in the wire har-
supply (voltage of power the ABS ECU to the front ness between the front
supply is low) wheel sensor is too low. wheel sensor and the
sor
assembly
64 Rear wheel sensor power Power voltage supplied from • Short circuit in the wire har-
supply (voltage of power the ABS ECU to the rear ness between the rear
supply is low) wheel sensor is too low. wheel sensor and the
sor
assembly
* The fault code number varies according to the vehicle conditions.

Fault code No. 11, 25
TIP
With the front wheel stopped, the rear wheel was rotated for longer than about 20 seconds (fault code
No. 11) or for longer than about 2 seconds (fault code No. 25).
Fault code No. 11

25
Item Front wheel sensor (intermittent pulses or no pulses)
Front wheel sensor signal is not received properly. (Pulses are not
Symptom
received or are received intermittently while the vehicle is traveling.)
Order Item/components and probable cause Check or maintenance job
1 Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the front wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE FRONT WHEEL” on page
4-24.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
lation of the rotor Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-26.
4 Defective front wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
8-176
Fault code No. 12

Fault code No. 12
Item Rear wheel sensor (intermittent pulses or no pulses)
Rear wheel sensor signal is not received properly. (Pulses are not
Symptom
received or are received intermittently while the vehicle is traveling.)
1 Foreign material adhered around the rear Check the surface of the sensor rotor and wheel sensor
2 Incorrect installation of the rear wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE REAR WHEEL” on page
4-35.
Refer to “MAINTENANCE OF THE REAR WHEEL
4 Defective rear wheel sensor or incorrect Check the wheel sensor for damage and the installed

TIP
• If the front brake ABS operates continuously for 20 seconds or more, fault code No. 26 will be record-
ed. If the front brake ABS operates continuously for 36 seconds or more, fault code No. 13 will be re-
corded.
• Vehicle possibly ridden on uneven roads.
13
Fault code No.
26
Item Front wheel sensor (abnormal pulse period)
Front wheel sensor signal is not received properly. (The pulse period
Symptom
is abnormal while the vehicle is traveling.)
bends.
4-24.
8-177
13
Fault code No.
26
Item Front wheel sensor (abnormal pulse period)
Symptom Front wheel sensor signal is not received properly. (The pulse period

TIP
• If the rear brake ABS operates continuously for 20 seconds or more, fault code No. 27 will be record-
ed. If the rear brake ABS operates continuously for 36 seconds or more, fault code No. 14 will be re-
corded.
• Vehicle possibly ridden on uneven roads.
14
Fault code No.
27
Item Rear wheel sensor (abnormal pulse period)
Rear wheel sensor signal is not received properly. (The pulse period
Symptom
bends.
4-35.
8-178
Fault code No. 15

TIP
Push the OFF/LOCK switch before disconnecting or connecting a coupler.
Fault code No. 15
Item Front wheel sensor (open or short circuit)
Symptom Open or short circuit is detected in the front wheel sensor.
1 Defective coupler between the front wheel • Check the coupler for any pins that may be pulled out.
sensor and the hydraulic unit assembly • Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.
2 Open or short circuit in the wire harness • Check for continuity between the white terminal “1”
between the front wheel sensor and the and the white terminal “4” and between the black ter-
hydraulic unit assembly minal “2” and the black terminal “5”.
• If there is no continuity, the wire harness is defective.
Replace the wire harness.
• Check that there is no short circuit between the white
terminal “1” and the black terminal “2” and between
the white terminal “4” and the black terminal “5”.
• If there is short circuit, the wire harness is defective.
• Check that there is no short circuit between the black
terminal “3” and the white terminal “4” and between
the black terminal “3” and the black terminal “5”.
1 2 3 4 5
R/W W B B W W/Y G/R W/G B

W B W Gy
R/L G/Y G G Br/W Lg/L Lg/W B/L B/G
6
7
6. ABS ECU
3 Defective front wheel sensor or hydraulic If the above items were performed and no malfunctions
unit assembly were found, the wheel sensor or hydraulic unit assembly
is defective. Replace the wheel sensor or hydraulic unit
assembly.
Refer to “FRONT WHEEL” on page 4-22 and “ABS
(Anti-lock Brake System)” on page 4-71.
8-179
Fault code No. 16

TIP
Fault code No. 16
Item Rear wheel sensor (open or short circuit)
Symptom Open or short circuit is detected in the rear wheel sensor.
1 Defective coupler between the rear wheel • Check the coupler for any pins that may be pulled out.
sensor and the hydraulic unit assembly • Check the locking condition of the coupler.
pler securely.
See TIP.
2 Open or short circuit in the wire harness • Check for continuity between the white terminal “1”
between the rear wheel sensor and the and the white terminal “4” and between the black ter-
hydraulic unit assembly minal “2” and the black terminal “5”.
• If there is no continuity, the wire harness is defective.
• Check that there is no short circuit between the white
terminal “1” and the black terminal “2” and between
the white terminal “4” and the black terminal “5”.
• Check that there is no short circuit between the black
terminal “3” and the white terminal “4” and between
the black terminal “3” and the black terminal “5”.
2 1 3 5 4

B W W Gy
6
7
6. ABS ECU
3 Defective rear wheel sensor or hydraulic If the above items were performed and no malfunctions
unit assembly were found, the wheel sensor or hydraulic unit assembly
is defective. Replace the wheel sensor or hydraulic unit
assembly.
Refer to “REAR WHEEL” on page 4-31 and “ABS (Anti-
lock Brake System)” on page 4-71.
8-180

TIP
If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, fault
code No. 17 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, fault code
No. 45 will be recorded first and fault code No. 17 will be recorded if the condition continues.
17
Fault code No.
45
Item Front wheel sensor (missing pulses)
Symptom Front wheel sensor signal is not received properly. (Missing pulses
are detected in the signal while the vehicle is traveling.)
bends.
4-24.

TIP
If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, fault
code No. 18 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, fault code
No. 46 will be recorded first and fault code No. 18 will be recorded if the condition continues.
Fault code No. 18

46
Item Rear wheel sensor (missing pulses)
Rear wheel sensor signal is not received properly. (Missing pulses

Symptom
bends.
4-35.
8-181
18
Fault code No.
46

Symptom
Fault code No. 21

Fault code No. 21
Item Hydraulic unit assembly (defective solenoid drive circuit)
Solenoid drive circuit in the hydraulic unit assembly is open or short-

Symptom
circuited.
1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.

Refer to “ABS (Anti-lock Brake System)” on page 4-71.
Fault code No. 24

Fault code No. 24
Item Brake light switch or tail/brake light
Brake light signal is not received properly while the vehicle is travel-
Symptom
ing. (Brake light circuit, or front or rear brake light switch circuit.)
1 Defective signaling system (tail/brake light Check the brake light switches.
or brake light switch) Refer to “CHECKING THE SWITCHES” on page 8-221.
2 Defective coupler between the signaling • Check the coupler for any pins that may be pulled out.
system (tail/brake light or brake light • Check the locking condition of the coupler.
switch) and the hydraulic unit assembly • If there is a malfunction, repair it and connect the cou-
pler securely.
3 Open or short circuit in the wire harness • Between ABS ECU coupler and joint coupler.
between the signaling system (tail/brake (Green–Yellow)
light or brake light switch) and the hydrau- • Between joint coupler and front brake light switch cou-
lic unit assembly pler.
(Green–Yellow)
• Between joint coupler and rear brake light switch cou-
pler.
(Green–Yellow)
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
8-182
Fault code No. 31

TIP
Fault code No. 31
Item Hydraulic unit assembly (abnormal ABS solenoid power supply)
Symptom Power is not supplied to the solenoid circuit in the hydraulic unit
assembly.
1 Blown ABS solenoid fuse Check the ABS solenoid fuse. If the ABS solenoid fuse
is blown, replace the fuse and check the wire harness.
2 Defective coupler between the battery • Check the locking condition of the coupler.
and the hydraulic unit assembly • If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.
3 Open or short circuit in the wire harness • Replace if there is an open or short circuit.
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS solenoid fuse.
assembly (Red/White–Red/White)
Fault code No. 32

Fault code No. 32
Hydraulic unit assembly (short circuit in ABS solenoid power supply

Item circuit)
Symptom Short circuit is detected in the solenoid power supply circuit in the
hydraulic unit assembly.

Fault code No. 33

TIP
Fault code No. 33
Item Hydraulic unit assembly (abnormal ABS motor power supply)
Power is not supplied to the motor circuit in the hydraulic unit

Symptom
assembly.
1 Blown ABS motor fuse Check the ABS motor fuse. If the ABS motor fuse is
blown, replace the fuse and check the wire harness.
8-183
Fault code No. 33
Item Hydraulic unit assembly (abnormal ABS motor power supply)
Power is not supplied to the motor circuit in the hydraulic unit

Symptom
assembly.
2 Defective coupler between the battery • Check the coupler for any pins that may be pulled out.
and the hydraulic unit assembly • Check the locking condition of the coupler.
pler securely.
See TIP.
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS motor fuse.
assembly (Red/Blue–Red/Blue)
• Between ABS ECU coupler and ground.
(Black/Green–Black/Green)
Fault code No. 34

Fault code No. 34
Hydraulic unit assembly (short circuit in ABS motor power supply

Item
circuit)
Short circuit is detected in the motor power supply circuit in the

Symptom hydraulic unit assembly.

Fault code No. 41

Fault code No. 41
Front wheel ABS (intermittent wheel speed pulses or incorrect

Item depressurization)
• Pulses from the front wheel sensor are received intermittently while
the vehicle is traveling.
Symptom • Front wheel will not recover from the locking tendency even though
the signal is transmitted from the ABS ECU to reduce the hydraulic
pressure.
sensor bends.
4-24.
2 Incorrect rotation of the front wheel Check that there is no brake disc drag on the front wheel
and make sure that it rotates smoothly.
4-24 and “CHECKING THE FRONT BRAKE DISCS” on
page 4-45.
8-184
Fault code No. 41
Front wheel ABS (intermittent wheel speed pulses or incorrect

Item
depressurization)
• Pulses from the front wheel sensor are received intermittently while
the vehicle is traveling.
Symptom • Front wheel will not recover from the locking tendency even though
pressure.
3 Front brake dragging Check that the brake fluid pressure is correctly transmit-
ted to the brake caliper when the front brake lever is
operated and that the pressure decreases when the
lever is released.
Refer to “CHECKING THE FRONT BRAKE DISCS” on
page 4-45.

42
Fault code No.
47
Rear wheel ABS (intermittent wheel speed pulses or incorrect

Item
depressurization)
• Pulses from the rear wheel sensor are received intermittently while
the vehicle is traveling. (for fault code No. 42)
Symptom • Rear wheel will not recover from the locking tendency even though
pressure.
sensor (for fault code No. 42) bends.
4-35.
2 Incorrect rotation of the rear wheel Check that there is no brake disc drag on the wheel and
make sure that it rotates smoothly.
4-35.
3 Rear brake dragging Check that the brake fluid pressure is correctly transmit-
ted to the brake caliper when the rear brake lever is
operated and that the pressure decreases when the
lever is released.
Refer to “CHECKING THE REAR BRAKE DISC” on
page 4-61.
8-185
Fault code No. 43

Fault code No. 43
Item Front wheel sensor (missing pulses)
Front wheel sensor signal is not received properly. (Missing pulses

Symptom
bends.
4-24.
Fault code No. 44

Fault code No. 44

Symptom
bends.
4-35.
8-186

51
Fault code No.
52
• Vehicle system power supply (voltage of ABS ECU power supply is

high) (for fault code No. 51)
Item
• Vehicle system power supply (voltage of wheel sensor power sup-
ply is high) (for fault code No. 52)
• Power voltage supplied to the ABS ECU in the hydraulic unit
assembly is too high. (for fault code No. 51)
Symptom
• Power voltage supplied to the wheel sensor is too high. (for fault
code No. 52)
1 Defective battery Recharge or replace the battery.

Refer to “CHECKING AND CHARGING THE BATTERY”
on page 8-230.
2 Disconnected battery terminal Check the connection. Replace or reconnect the termi-
nal if necessary.
3 Defective charging system Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-19.
Fault code No. 53

TIP
Fault code No. 53
Vehicle system power supply (voltage of ABS ECU power supply is

Item
low)
Power voltage supplied to the ABS ECU in the hydraulic unit assem-
Symptom
bly is too low.

on page 8-230.
pler securely.
See TIP.
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS ECU fuse.
assembly (Brown/White–Brown/White)
8-187
Fault code No. 54

TIP
Fault code No. 54
Hydraulic unit assembly (defective ABS solenoid and ABS motor

Item
power supply circuits)
Abnormality is detected in the solenoid or motor power supply cir-

Symptom
cuit in the hydraulic unit assembly.

on page 8-230.
pler securely.
See TIP.
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS motor fuse.
assembly (Red/Blue–Red/Blue)
• Between ABS ECU coupler and ABS solenoid fuse.
(Red/White–Red/White)
Fault code No. 55

Fault code No. 55
Item Hydraulic unit assembly (defective ABS ECU)
Symptom Abnormal data is detected in the hydraulic unit assembly.

Fault code No. 56

Fault code No. 56
Item Hydraulic unit assembly (abnormal internal power supply)
Abnormality is detected in the power supply circuit in the hydraulic

Symptom
unit assembly.

8-188
Fault code No. 63

Fault code No. 63
Item Front wheel sensor power supply (voltage of power supply is low)
Power voltage supplied from the ABS ECU to the front wheel sensor
Symptom
is too low.
1 Short circuit in the wire harness between • Check that there is no short circuit between the white
the front wheel sensor and the hydraulic terminal “1” and the black terminal “2”.
unit assembly • Check that there is no short circuit between the black
terminal “3” and the white terminal “1”.
• If there is a short circuit, the wire harness is defective.
3 1 2

W B W Gy
4
5
4. ABS ECU
2 Defective front wheel sensor • Check that there is no short circuit between the gray
• If there is a short circuit, the wheel sensor is defective.
Repair or replace the wheel sensor.
2 1

W B W Gy
3
4
3. ABS ECU
8-189
Fault code No. 64

Fault code No. 64
Item Rear wheel sensor power supply (voltage of power supply is low)
Power voltage supplied from the ABS ECU to the rear wheel sensor
Symptom
is too low.
1 Short circuit in the wire harness between • Check that there is no short circuit between the white
the rear wheel sensor and the hydraulic terminal “1” and the black terminal “2”.
unit assembly • Check that there is no short circuit between the black
• If there is a short circuit, the wire harness is defective.
3 2 1

B W W Gy
4
5
4. ABS ECU
2 Defective rear wheel sensor • Check that there is no short circuit between the gray
• If there is a short circuit, the wheel sensor is defective.
Repair or replace the wheel sensor.
2 1

B W W Gy
3
4
3. ABS ECU
8-190
EAS31167
[B-3] DELETING THE FAULT CODES

To delete the fault codes, use the Yamaha diagnostic tool. For information about deleting the fault
codes, refer to the operation manual of the Yamaha diagnostic tool.
Check that all the displayed fault codes are deleted.
90890-03256
90890-03254

Remove the protective cap, and then connect the Yamaha diagnostic tool to the coupler “1”.
EAS31168
[C-1] FINAL CHECK

Check all the following items to complete the inspection.
If the process is not completed properly, start again from the beginning.
Checking procedures
1. Check the brake fluid level in the brake master cylinder reservoir and brake fluid reservoir.
Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-15.
2. Check the wheel sensors for proper installation.
Refer to “INSTALLING THE FRONT WHEEL (DISC BRAKE)” on page 4-28 and “INSTALLING THE
REAR WHEEL (DISC BRAKE)” on page 4-36.
3. Perform brake line routing confirmation.
Refer to “HYDRAULIC UNIT OPERATION TEST” on page 4-75.
If it does not have reaction-force properly, the brake hose is not properly routed or connected.
4. Delete the fault codes.
Refer to “[B-3] DELETING THE FAULT CODES” on page 8-191.
5. Checking the ABS warning light.
Refer to “CHECKING THE ABS WARNING LIGHT” on page 4-78.
If the ABS warning light does not turn off, the possible causes are following:
• The problem is not solved.
• Open circuit between the ABS ECU and the meter assembly.
Check for continuity between green/red terminal of the ABS ECU coupler and green/red terminal of
the meter assembly coupler.
• Malfunction in the meter assembly circuit.
• Malfunction in the ABS warning light circuit in the hydraulic unit assembly.
8-191
8-192
SMART KEY SYSTEM
EAS20201
SMART KEY SYSTEM

EAS31452
CIRCUIT DIAGRAM
XP530E-A
8-193
SMART KEY SYSTEM
3. Seat lock fuse

4. Joint coupler
6. OFF/LOCK switch
7. Parking/Unlock switch
8. Buzzer
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
25.Backup fuse
34.Centerstand lock solenoid
36.Steering lock unit
37.Anti-theft alarm (OPTION)
53.ON/start switch
54.Hazard switch
73.Seat/fuel lid lock solenoid
75.Meter assembly
76.Smart key system indicator light
A. Wire harness
D. Headlight sub-wire harness (headlight har-
ness)
8-194
SMART KEY SYSTEM
XP530-A
8-195
SMART KEY SYSTEM
3. Seat lock fuse

4. Joint coupler
6. OFF/LOCK switch
8. Buzzer
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
25.Backup fuse
53.ON/start switch
54.Hazard switch
74.Storage compartment lid lock solenoid
77.Meter assembly
A. Wire harness
ness)
8-196
SMART KEY SYSTEM
XP530D-A
8-197
SMART KEY SYSTEM
3. Windshield motor fuse

4. Joint coupler
6. OFF/LOCK switch
8. Buzzer
15.Battery
17.Main fuse
19.Engine ground
21.Ignition fuse
25.Backup fuse
54.ON/start switch
55.Hazard switch
80.Storage compartment lid lock solenoid
87.Meter assembly
A. Wire harness
ness)
8-198
SMART KEY SYSTEM
EAS31453
TROUBLESHOOTING
Vehicle power does not turn on. (Meter light and tail/brake light do not come on.)
Engine does not start even though vehicle power is turned on.
Seat/fuel lid or storage compartment lid (for XP530-A/XP530D-A) does not open. (Vehicle power is
turned on.)
TIP
Before troubleshooting, remove the following part(s):
2. Handlebar cover (front)
3. Storage box
Checking the vehicle power
1. Check the smart key.

 The smart key indicator light
comes on when the ON/OFF switch
Replace the button cell battery of the
“ ” is pushed.
NG smart key. Standard battery: CR2025
 Check the button cell battery.
Refer to “CHECKING THE SMART
KEY BATTERY” on page 8-250.
OK
2. Check the fuses.
(Main, backup, and ignition)
on page 8-229.
OK
page 8-230.
OK
4. Check the ON/start switch.
The ON/start switch is faulty. Replace the
OK
OK
6. Check the entire smart key system’s
page 8-193.
OK
8-199
SMART KEY SYSTEM
Checking the smart key system

Before checking the smart key system, make sure that the smart key is located within the operating
range of the smart key system and that the key is turned on.
Vehicle power does not turn on. (Meter light and tail/brake light do not come on.)
TIP
• Before performing this procedure, make sure that there are no sources of strong electromagnetic
waves in the vicinity. (Because the amount of electromagnetic waves will change if the vehicle is
moved a short distance, move the vehicle away from sources of strong electromagnetic waves before
performing the procedure.)
• Use the smart key that is registered to the vehicle.
1. Check the vehicle power.

Refer to “Checking the vehicle pow- Repair or replace any defective parts.
er”. NG
OK
• The vehicle can be operated in the emer-
gency mode.  Replace the smart key
or remote control unit.
• The vehicle cannot be turned on in the
2. Check that the smart key system in-
emergency mode, but the storage box
dicator light “ ” flashes when the
YES light comes on when the seat is opened.
ON/start switch is pushed.
 Replace the remote control unit.
• The storage box light does not come on
when the seat is opened.  Replace the
seat or storage box light.
NO
3. The smart key system indicator light
• The steering lock is stuck and cannot be
“ ” flashes.
released.
(The indicator light flashes once ev-
• Release the steering lock.  Try moving
ery 2 seconds, and then goes off af-
YES the handlebar gently to the left or right.
ter approximately 20 seconds.)
• The steering lock is not stuck.  Re-
Refer to “SMART KEY SYSTEM
place the steering lock unit.
SELF-DIAGNOSIS” on page 8-205.
NO
4. The smart key system indicator light • A steering lock communication error has
“ ” flashes. occurred.
(The indicator light repeatedly flash- • Check for an open or short circuit be-
es 2 times, and then goes off after tween the steering lock unit and the re-
approximately 20 seconds.) YES mote control unit (Light green/Blue–Light
Refer to “SMART KEY SYSTEM green/Blue).  Repair or replace any
SELF-DIAGNOSIS” on page 8-205. defective parts.
NO
8-200
SMART KEY SYSTEM
5. The smart key system indicator light

“ ” flashes.
(The indicator light repeatedly flash-
Steering lock unit data error or malfunction
es 3 times, and then goes off after
YES  Replace the steering lock unit.
approximately 20 seconds.)
NO
• The smart key system indicator light
“ ” does not flash.
• There are sources of strong electro-
magnetic waves in the vicinity 
Move the vehicle.
• Smart key malfunction  Register
and use a different smart key.
• Remote control unit malfunction 
Engine does not start even though vehicle power is turned on.
1. When the vehicle power is turned
Check and repair the electric starting sys-
on, the smart key system indicator
tem.
light “ ” flashes.
NO Refer to “ELECTRIC STARTING
SYSTEM” on page 8-9.
YES
2. Check for continuity in the commu-
nication line between the ECU and
the remote control unit (Yel- NG
low/Blue).
OK
• Check the engine.
Refer to “FUEL INJECTION
SYSTEM” on page 8-55.
• Replace the ECU.
• Replace the remote control unit.
Seat/fuel lid does not open. (Vehicle power is turned on.)

TIP
If the smart key system indicator light “ ” comes on for 0.3 second, goes off for 1.0 second, and this
pattern continues for 20 seconds (error) when the seat/fuel lid is opened, the seat/fuel lid cannot be
opened unless the vehicle power is turned off and then on.

er”. NG
OK
8-201
SMART KEY SYSTEM
2. Check the OFF/LOCK switch and

Parking/Unlock switch. Replace the OFF/LOCK switch and/or
Refer to “CHECKING THE NG Parking/Unlock switch.
OK
Communication between the remote con-
Parking/Unlock switch on the vehi-
trol unit and meter is not possible. 
cle is operated.
Check the wire harness (Light
(Comes on for 0.3 second, goes off
YES green/Green–Light green/White) and/or
for 1.0 second, and this pattern con-
replace the remote control unit and/or me-
tinues for 20 seconds.)
ter.
NO
• The seat/fuel lid cannot be opened.
• Check the mechanical components
of the lock for malfunctions. Repair
or replace any defective parts.
• Check the seat/fuel lid lock solenoid.
SEAT/FUEL LID LOCK SOLENOID”
on page 8-250.  Replace the re-
mote control unit and/or meter.
Storage compartment lid (for XP530-A/XP530D-A) does not open. (Vehicle power is turned on.)
TIP
If the smart key system indicator light “ ” comes on for 0.3 second, goes off for 1.0 second, and this
pattern continues for 20 seconds (error) when the storage compartment is opened, the storage com-
partment cannot be opened unless the vehicle power is turned off and then on.

er”. NG
OK
Parking/Unlock switch. Replace the OFF/LOCK switch and Park-
Refer to “CHECKING THE NG ing/Unlock switch.
OK
8-202
SMART KEY SYSTEM

trol unit and meter is not possible. 
Parking/Unlock switch on the vehi-
Check the wire harness (Light
cle is operated.
(Comes on for 0.3 second, goes off
replace the remote control unit and/or me-
for 1.0 second, and this pattern con-
ter.
tinues for 20 seconds.)
NO
• The storage compartment cannot be
opened.
or replace any defective parts.
• Check the storage compartment lid
solenoid (for XP530-A/XP530D-A).
Refer to “CHECKING THE STOR-
AGE COMPARTMENT LID LOCK
SOLENOID (for XP530-A/XP530D-
A)” on page 8-251.  Replace the
remote control unit and/or meter.
The turn signal light fails to blink (parking mode operation).
1. Check the turn signal/hazard relay.

Refer to “CHECKING THE RE- Replace the turn signal/hazard relay.
OK
2. Check for open or short circuit be-
tween the remote control unit and Replace the wire harness.
turn signal/hazard relay (Brown). NG
OK
Centerstand does not unlock. (Vehicle power is turned on.)
TIP
If the smart key system indicator light “ ” flashes (error, refer to “SMART KEY SYSTEM SELF-DIAG-
NOSIS” on page 8-205.) when the centerstand is unlocked, the centerstand cannot be unlocked if the
vehicle power is not turned off and on.

er”. NG
OK
ON/start switch. Replace the OFF/LOCK switch and
Refer to “CHECKING THE NG ON/start switch.
OK
8-203
SMART KEY SYSTEM

trol unit and centerstand lock unit is not
ON/start switch on the vehicle is op-
possible.  Check the wire harness (Light
erated.
(Refer to “SMART KEY SYSTEM
replace the remote control unit and/or cen-
SELF-DIAGNOSIS” on page
terstand lock unit.
8-205.)
NO
• The centerstand cannot be un-
locked.
or replace any defective parts. 
Replace the remote control unit
and/or centerstand lock unit.
8-204
SMART KEY SYSTEM
EAS31534
SMART KEY SYSTEM SELF-DIAGNOSIS

The smart key system is equipped with a self-diagnostic function. If a malfunction is detected in the sys-
tem, the malfunction will be indicated by the flash pattern of the smart key system indicator light “ ”.
TIP
The smart key system indicator light “ ” comes on for 1 second when the ON/start switch is pushed. If
one of the following malfunctions is detected, the indicator light starts flashing.
Flashing time/number Malfunction and

Item Flash pattern
of flashes check point
0.5 (s)
a Replace the button cell
battery of the smart key.
Low voltage of smart b 20 (seconds) Refer to “SMART KEY
key button cell battery 0.5 (s)
SYSTEM” on page
8-193.
a. LED on
b. LED off
The smart key cannot
0.15 (s) be recognized.
a Check that there are no
sources of strong elec-
Vehicle power off verifi- b 10 (seconds) tromagnetic waves in
cation error 0.15 (s)
the vicinity, the smart
key is not lost, and the
a. LED on battery is not dis-
b. LED off charged.
The smart key cannot
0.15 (s) be recognized.
a Check that there are no
Running detection Flashes continuously sources of strong elec-
b until the error is tromagnetic waves in
error* 0.15 (s)
resolved. the vicinity, the smart
key is not lost, and the
a. LED on battery is not dis-
b. LED off charged.
• Steering lock is stuck
• Steering lock cannot 0.5 (s)
be released a
b Check whether the
20 (seconds)/10 times
1.5 (s) steering lock is stuck.
a. LED on
b. LED off
0.3 (s)
a
Steering lock or center- 20 (seconds)/flashes 2
stand lock communica- b 1.0 (s) times in a repeating Check the wire harness.
tion error 0.3 (s) cycle
a. LED on
b. LED off
• Steering lock data
error 0.3 (s)
• Steering lock unit mal- a
function 20 (seconds)/flashes 3 Check the wire harness.
b times in a repeating Check the steering lock
0.3 (s) 1.0 (s) cycle unit.
a. LED on
b. LED off
8-205
SMART KEY SYSTEM
Flashing time/number Malfunction and

Item Flash pattern
of flashes check point
• ECU communication
error 0.3 (s)
• Data error Flashes continuously
a Check the wire harness.
• ECU malfunction until the error is Check the ECU.
b resolved/flashes 4
0.3 (s) 1.0 (s) Check the remote con-
times in a repeating
trol unit.
cycle.
a. LED on
b. LED off
0.25 (s)
Steering lock abnormal a
or centerstand lock b Check whether the
10 seconds
abnormal (end position 0.25 (s) steering lock is stuck.
contact)
a. LED on
b. LED off
Check the steering lock

0.3 (s)
unit or centerstand lock
a unit.
Steering lock abnormal 20 (seconds)/flashes 5
b Error continues 
or centerstand lock times in a repeating
abnormal (others) 0.3 (s) 1.0 (s) cycle. Replace the steering
lock unit, centerstand
a. LED on lock unit, and/or remote
b. LED off control unit.
0.3 (s)
a
Communication error
between remote control b 20 seconds Check the wire harness.
1.0 (s)
unit and meter
a. LED on
b. LED off
* The running detection error

If the smart key is dropped or can no longer be recognized while the vehicle is traveling. If the vehicle
travels 1 km or more while the smart key cannot be recognized, the smart key system indicator light
“ ” flashes in 0.15-second intervals.
The vehicle can be ridden, but the vehicle power cannot be turned off.
Although a forced shutdown can be performed to turn off the vehicle power (the OFF/LOCK switch
is pushed briefly while the smart key system indicator light “ ” is flashing in 0.15 second intervals),
the vehicle power cannot be turned back on.
8-206
SMART KEY SYSTEM
EAS31535
SMART KEY SYSTEM EMERGENCY MODE

When the smart key is lost, damaged, or its battery has discharged, the vehicle can still be turned on
and the engine started. You will need a mechanical key and the smart key system identification number.
To operate the vehicle in emergency mode, carry out the following steps.
TIP
Emergency mode operation will be cancelled if the respective steps are not carried out within the time
set for each operation or if the OFF/LOCK switch is pushed.
1. Stop the vehicle in a safe place.
2. Unlock the seat by inserting the mechanical key into the lock located right side of body and turn it
counter clockwise.
3. Open the seat and check that the trunk light comes on.
4. Push the ON/start switch once.
5. Without completely shutting the seat, raise and lower it three times within 10 seconds.
TIP
Use the rear storage compartment light as a guide when raising and lowering the seat.
The smart key system indicator light “ ” on the speedometer will come on for three seconds to in-
dicate the transition to emergency mode.
1. Smart key system indicator light “ ”

6. After the smart key system indicator light “ ” goes off, use the Parking/Unlock switch to enter the
identification number. Refer to the following procedure on how to input the identification number.
1. Identification number
8-207
SMART KEY SYSTEM
7. Inputting the identification number is done by counting the number of flashes of the smart key system
indicator light “ ”.
For example, if the identification number is 123456:
Push and hold the Parking/Unlock switch.

The smart key system indicator light “ ” will start to flash.

Release the Parking/Unlock switch after the smart key system indicator light “ ” flashes once.

The first digit of the identification number has been set as “1”.

Push and hold the Parking/Unlock switch again.

Release the Parking/Unlock switch after the smart key system indicator light “ ” flashes twice.

The second digit has been set as “2”.

Repeat the above procedure until all digits of the identification number have been set. The smart key
system indicator light “ ” will flash for 10 seconds if the correct identification number was entered.
TIP
Emergency mode will be terminated when either one of the following situations apply. In this case, start
over again from step (4).
• When there are no Parking/Unlock switch operations for 10 seconds during the identification number
input process.
• When the smart key system indicator light “ ” is allowed to flash 10 or more times.
8. Push the ON/start switch while the smart key system indicator light “ ” is flashing to turn on the pow-
er to the vehicle. The engine can now be started.
TIP
• If the identification number is not correctly entered, the smart key system indicator light “ ” will flash
rapidly for 3 seconds and emergency mode is terminated. In this case, start over again from step (4).
• To lock the handlebar after turning on the vehicle in emergency mode, turn the vehicle power off, wait
30 seconds, and then turn the handlebar to the left and push the OFF/LOCK switch.
8-208
SMART KEY SYSTEM
EAS31536
REGISTERING A SMART KEY

The following procedure can be used to register additional smart keys or a new smart key in case the
original smart key is lost.
TIP
• A maximum of 6 smart keys can be registered to the remote control unit.
• Be sure to register the smart keys one at a time. Do not register multiple smart keys at the same time.
1. Place the smart key “1” that will be registered within 80 cm (31.5 in) “a” of the remote control unit.
1
a
2. Perform steps (1) to (7) in “SMART KEY SYSTEM EMERGENCY MODE” on page 8-207.
3. While the smart key system indicator light “ ” is on for 10 seconds, push the Parking/Unlock switch
“1” and OFF/LOCK switch “2” alternately 3 times (total of 6 times).
TIP
Either switch can be pushed first.
1 2
4. The smart key indicator light (red) “1” on the new smart key comes on for 10 seconds.
TIP
While the smart key indicator light on the smart key is on, the smart key system indicator light “ ” flash-
es according to the number of currently registered smart keys. (For example, if 5 smart keys are regis-
tered, the indicator light flashes 5 times.)
5. While the smart key indicator light is on for 10 seconds, push the ON/OFF switch “ ” on the smart
key to transmit a signal from the smart key to the remote control unit.
8-209
SMART KEY SYSTEM
6. If the smart key is registered successfully, the smart key system indicator light “ ” will come on for
3 seconds, and then the smart key system will turn off.
If the smart key was not registered successfully, the smart key system indicator light “ ” will flash
for 3 seconds, and then the smart key system will turn off.
TIP
If this registration procedure is performed for a smart key that is already registered, the smart key sys-
tem indicator light “ ” will flash for 7 seconds (on for 0.2 second and off for 0.8 second).
EAS31537
DISABLING A SMART KEY

If a smart key is lost or stolen, the smart key can be disabled.
1. Place all of the smart keys “1” 300 cm (118.1 in) “a” or more away from the vehicle or lock the com-
munication.
2. Perform steps (1) to (7) in “SMART KEY SYSTEM EMERGENCY MODE” on page 8-207.
3. While the smart key system indicator light “ ” is on for 10 seconds, perform the following procedure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While pushing the OFF/LOCK switch “1”, push the Parking/Unlock switch “2” 3 times. Then, release
both switches.
2 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check that the smart key system indicator light “ ” goes off (the smart key disable mode is activat-
ed).
5. Turn on (unlocked setting) the smart keys that you want to enable and place them within 80 cm (31.5
in) of the remote control unit.
6. Push the OFF/LOCK switch 1 time to start the communication between the remote control unit and
the smart keys that are located within 80 cm (31.5 in) of the unit.
TIP
The number of smart keys that currently can be used will be indicated.
Number of flashes = Number of verified smart keys. (1 cycle of on for 0.3 second and off for 0.3 second
= 1 smart key)
8-210
SMART KEY SYSTEM
7. Push the OFF/LOCK switch and Parking/Unlock switch simultaneously for 2 seconds. The use of
only the verified smart keys will be enabled. The use of all other smart keys will be disabled.
TIP
If the procedure was not completed successfully, repeat the procedure from step (1).
EAS32446
REPLACING THE REMOTE CONTROL UNIT, STEERING LOCK, AND ECU

TIP
The remote control unit, steering lock, and ECU cannot be replaced at the same time.
EAS32447
REPLACING THE REMOTE CONTROL UNIT

1. Replace the remote control unit, and then place only 1 previously used smart key within 80 cm (31.5
in) of the remote control unit.
2. Push the ON/start switch.
3. Push the OFF/LOCK switch, and then push the ON/start switch to check that the operation is correct.
4. Register any additional smart keys.
TIP
• If multiple smart keys were registered to the previous remote control unit, perform the preceding pro-
cedure for only 1 smart key. Do not perform the procedure for multiple smart keys at the same time.
• If the smart key identification number matches, it can be determined that the replacement procedure
is being performed for a legitimate user. Write the remote control unit identification number and smart
key identification number to the remote control unit and overwrite the smart identification number on
the smart key with the new number.
EAS31556
REPLACING THE STEERING LOCK UNIT

1. Replace the steering lock unit, and then place the previously used smart key within 80 cm (31.5 in)
of the remote control unit.
TIP
An identification number is not written to the steering lock unit when it is shipped from the factory. When
the vehicle system is turned on for the first time, the remote control unit identification number and smart
key identification number are automatically registered from the remote control unit to the steering lock
unit.
EAS31541
REPLACING THE ECU

1. Replace the ECU, and then place the previously used smart key within 80 cm (31.5 in) of the remote
control unit.
TIP
An identification number is not written to the ECU when it is shipped from the factory. When the vehicle
system is turned on for the first time, the remote control unit identification number is automatically writ-
ten from the remote control unit to the ECU.
8-211
SMART KEY SYSTEM
EAS31719
REPLACEMENT PARTS LIST

TIP
When replacing the parts, refer to the following sections.
• Refer to “SMART KEY SYSTEM EMERGENCY MODE” on page 8-207.
• Refer to “REGISTERING A SMART KEY” on page 8-209.
• Refer to “REPLACING THE REMOTE CONTROL UNIT, STEERING LOCK, AND ECU” on page
8-211.
• Refer to “REPLACING THE REMOTE CONTROL UNIT” on page 8-211.
• Refer to “REPLACING THE STEERING LOCK UNIT” on page 8-211.
• Refer to “REPLACING THE ECU” on page 8-211.
Required item when Replacement parts (when an item is required

replacing parts in order to replace parts)
 : Required.  : Replace.
Smart key identi-

 : fication number : Do not replace.
or smart key is
Faulty part required. Remarks
: Not required. *: This part must be replaced even if it is

not faulty.
Smart key
Remote
identifica- Smart key Smart control Steering ECU
tion num- key lock unit
ber unit
Register the smart key identifica-

Smart key       tion number in the emergency
mode.
When the vehicle system is

turned on, the smart key identifi-
Remote control unit       cation number is automatically
registered to the remote control
unit.

Steering lock unit       cation number is automatically
registered to the steering lock
unit.

ECU       cation number is automatically
registered to the ECU.
Steering lock turned on, the smart key identifi-
      cation number is automatically
unit/ECU registered to the steering lock
unit and ECU.

Remote control turned on, the smart key identifi-
      cation number is automatically
unit/ECU registered to the remote control
unit and ECU.
The original smart keys can be

Remote control used if they are registered as
additional smart keys. Replace
unit/Steering lock   *   * the smart key, remote control
unit
unit, steering lock unit, and ECU
as a set.
Replace the smart key, remote
Smart key/Remote     * * control unit, steering lock unit,
control unit and ECU as a set.
8-212
SMART KEY SYSTEM
Required item when Replacement parts (when an item is required

replacing parts in order to replace parts)
 : Required.  : Replace.
Smart key identi-

fication number
 : or smart key is : Do not replace.
Faulty part required. Remarks
This part must be replaced even if it is

: Not required. *: not faulty.
Smart key Remote

identifica- Smart Steering
tion num- Smart key key control lock unit ECU
unit
ber

tion number in the emergency
mode.
Smart key/Steering When the vehicle system is
lock unit       turned on, the smart key identifi-
cation number is automatically
unit.

mode.
Smart key/ECU       When the vehicle system is
registered to the ECU.
Remote control Replace the smart key, remote

unit/Steering lock control unit, steering lock unit,
unit/ECU/(Smart       and ECU as a set.
key)
Smart key/Remote Replace the smart key, remote
control unit/Steering      * control unit, steering lock unit,
lock unit and ECU as a set.
Smart key/Remote Replace the smart key, remote

    *  control unit, steering lock unit,
control unit/ECU and ECU as a set.

mode.
Smart key/Steering When the vehicle system is
lock unit/ECU       turned on, the smart key identifi-
unit and ECU.
TIP
When replacing the centerstand lock unit, it is not necessary to replace the other parts at the same time.
8-213
SMART KEY SYSTEM
8-214
ELECTRICAL COMPONENTS
EAS20089
5
4 6
3
7
20
10
19
18
11
17
12
16
15
13
14
8-215

2. Hydraulic unit assembly
3. Buzzer
4. Intake air temperature sensor
6. Battery
7. Steering lock unit
8. Diode 3
9. Diode 5
10.Injector
12.Spark plug
13.Spark plug cap
18.Diode 1
19.Ignition coil
20.Smart key system relay (unlock)/Smart key
system relay (lock)/Headlight relay (dimmer)
/Brake light relay (for XP530D-A)/Fuel injec-
tion system relay/Steering lock relay/Starting
circuit cut-off relay/Ignition system relay
8-216
2
4
5
1
13
12
7
11
10
8
9
8-217
1. Fuel pump
2. Seat/fuel lid lock solenoid
3. Seat heater (for XP530D-A)
4. Storage box light switch
5. Sidestand relay/Turn signal/hazard
relay/Radiator fan motor relay/Seat heater
relay (power) (for XP530D-A)/Seat heater
relay (control) (for XP530D-A)/Windshield
drive unit relay (down) (for XP530D-A)/Wind-
shield drive unit relay (up) (for XP530D-A)
6. Diode 2
8. Centerstand lock solenoid
9. Starter motor
10.O2 sensor
11.Stator coil
13.Sidestand switch
8-218
7 8
6
5
9
4
10
3
11
12
2 13
1
14
22
15
21
20
19
16
18
17
8-219
1. Front brake light switch (for XP530E-

A/XP530-A)
2. Front brake light switch (for XP530D-A)
3. Grip warmer (for XP530D-A)
5. OFF/LOCK switch
6. Rear brake light switch (for XP530E-
A/XP530-A)
7. Rear brake light switch (for XP530D-A)
8. Starter relay
9. Fuse box 4 (Brake light fuse) (for XP530D-A)
/Fuse box 5 (Cruise control fuse) (for
XP530D-A)
10.Fuse box 1
11.Fuse box 2
12.Fuse box 3
13.Diode (fuse box 2)
14.Remote control unit
15.Auxiliary DC jack
16.Windshield drive unit
17.Horn
21.Storage compartment lid lock solenoid (for
XP530-A/XP530D-A)
8-220
EAS30549
CHECKING THE SWITCHES

XP530E-A
1 2 8 9
B L/B B Br P R/B R/W L/W B
PASS
10
3 4 Br/W Br/Y
W/L B/W W/R B/W W/G
FREE UP
PUSH (Neutral)
DOWN 11
5 6
Ch Br/W Dg
G/Y Br
N
G/Y Br
R/W Br/Y
L/W B G/Y Br
Ch Dg R/B Br/W
W/L Br/W W/G W/R Br
G/Y Br
B/W P B L/B
12
L
L B
7
13
B
B B
L
L B
R
B
14
R
R L/G
L/G
8-221
1. Dimmer/pass switch
2. Horn switch
3. Menu switch
4. Select switch
5. Turn signal switch
7. Sidestand switch
9. ON/start switch
10.Hazard switch
12.OFF/LOCK switch
13.Parking/Unlock switch
8-222
XP530-A
1 2 8 9
B L/B B Br P R/B R/W L/W B
PASS
10 11
3 4 Br/W Br/Y B/W W/G
W/L B/W W/R B/W W/G FREE
FREE UP PUSH
PUSH (Neutral)
DOWN 12
5 6
Ch Br/W Dg
G/Y Br
N
G/Y Br
L/W B R/W Br/Y

G/Y Br
Ch Dg W/G B/W R/B Br/W
W/L Br/W W/G W/R Br
G/Y Br
B/W P B L/B
13
L
L B
7
14
B
B B
L
L B
B
B
15
R
R L/G
L/G
8-223
2. Horn switch
3. Menu switch
4. Select switch
7. Sidestand switch
9. ON/start switch
10.Hazard switch
11.Mode switch
13.OFF/LOCK switch
8-224
XP530D-A
1 2 9 10 11 12
Y/B O/W R/G Y/B G/L G/W G/Y Y/B Y/W G/W G/Y Y/W Y/W R/B R/W L/W B
PUSH RES OFF OFF
FREE FREE ON ON
SET
Y/B G/W Y/W G/W
3 4 Y/W G/Y Y/W G/Y
13 14
B L/B B Br P Br/W Br/Y B/W W/G
FREE
PUSH
PASS
5 6
W/L B/W W/R B/W W/G L/W B R/W Br/Y
FREE UP
W/G B/W R/B Br/W
PUSH (Neutral)
DOWN
7
Ch Br/W Dg
N 15
L
L B
O/W Y/B Ch Dg W/G W/R Br

B/W W/L G/L Br/L Br/W P B L/B
L
16
(B) L B
8
B 17
B R B
B B
R
R
18
R
R L/G
L/G
8-225
1. Cruise control power switch

2. Cruise control setting switch
4. Horn switch
5. Menu switch
6. Select switch
8. Sidestand switch
12.ON/start switch
13.Hazard switch
14.Mode switch
15.OFF/LOCK switch
8-226
Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace the switch.
ECA18520
NOTICE
Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from
the opposite end of the coupler, taking care not to loosen or damage the leads.

90890-03243
eter
YU-A1927
TIP
• Before checking for continuity, set the digital circuit tester to “0” and to the “  ” range.
• When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the ON/start
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
“ ”.
There is continuity between Blue/White and Black when the switch is set to “ON”.
b b
L/W B L/W B
a a
L/W B L/W B
W/G B/W
A. XP530E-A
B. XP530-A/XP530D-A
8-227
EAS30550
ly affected. If the headlight bulb gets soiled,
CHECKING THE BULBS AND BULB thoroughly clean it with a cloth moistened
SOCKETS with alcohol or lacquer thinner.
TIP
Do not check any of the lights that use LEDs. 2. Check:
• Bulb (for continuity)
Check each bulb and bulb socket for damage or (with the digital circuit tester)
wear, proper connections, and also for continuity No continuity  Replace.
between the terminals.
Damage/wear  Repair or replace the bulb, Digital circuit tester (CD732)
bulb socket or both. 90890-03243
Improperly connected  Properly connect. Model 88 Multimeter with tachom-
No continuity  Repair or replace the bulb, bulb eter
socket or both. YU-A1927
Types of bulbs
TIP
The bulbs used on this vehicle are shown in the
Before checking for continuity, set the digital cir-
illustration.
cuit tester to “0” and to the “” range.
• Bulbs “a” are used for turn signal lights and can
be removed from the socket by pushing and ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
turning the bulb counterclockwise. a. Connect the positive tester probe to terminal
• Bulbs “b” are used for license plate and storage “1” and the negative tester probe to terminal
box lights and can be removed from their re- “2”, and check the continuity.
spective socket by carefully pulling them out. b. If reading indicate no continuity, replace the
bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a b
Checking the condition of the bulbs

bulbs. Checking the condition of the bulb sockets
1. Remove: The following procedure applies to all of the bulb
• Bulb sockets.
EWA17540
WARNING 1. Check:
• Bulb socket (for continuity)
Since headlight bulbs get extremely hot,
(with the digital circuit tester)
keep flammable products and your hands
No continuity  Replace.
away from them until they have cooled
down. Digital circuit tester (CD732)
ECA14381 90890-03243
NOTICE Model 88 Multimeter with tachom-
• Be sure to hold the socket firmly when re- eter
YU-A1927
moving the bulb. Never pull the lead, other-
wise it may be pulled out of the terminal in
TIP
the coupler. Check each bulb socket for continuity in the
• Avoid touching the glass part of a headlight same manner as described in the bulb section,
bulb to keep it free from oil, otherwise the however, note the following.
transparency of the glass, the life of the
bulb, and the luminous flux will be adverse-
8-228
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Amperage
a. Install a good bulb into the bulb socket. Fuses Q’ty
rating
b. Connect the digital circuit tester probes to the
respective leads of the bulb socket. Headlight 7.5 A 1
c. Check the bulb socket for continuity. If any of Taillight 7.5 A 1
the readings indicate no continuity, replace Electronic throttle valve 7.5 A 1
the bulb socket.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Signaling system 7.5 A 1
Ignition 7.5 A 1
EAS30551
CHECKING THE FUSES Radiator fan motor 15 A 1

The following procedure applies to all of the fus- Fuel injection system 7.5 A 1
es.
ECA25770 ABS motor 30 A 1
NOTICE
ABS control unit 7.5 A 1
To avoid a short circuit, always push the
ABS solenoid 15 A 1
OFF/LOCK switch when checking or replac-
ing a fuse. Backup 15 A 1
1. Remove: Auxiliary DC jack 2A 1
• Front cover Seat lock (for XP530E-
Refer to “GENERAL CHASSIS (1)” on page 7.5 A 1
A/XP530-A)
4-1.
Windshield motor (for 20 A 1
2. Check: XP530D-A)
• Fuse
Brake light (for XP530D-A) 1A 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the digital circuit tester to the fuse Cruise control (for 1A 1
and check the continuity. XP530D-A)
TIP Spare 40 A 1
Set the digital circuit tester selector to “  ”.
Spare 30 A 1
Digital circuit tester (CD732) Spare 1A 1

90890-03243 Spare 15 A 1
eter Spare (for XP530D-A) 20 A 1
YU-A1927 Spare 7.5 A 1
b. If the digital circuit tester indicates “O.L”, re- Spare 2A 1

place the fuse. EWA13310
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ WARNING
3. Replace: Never use a fuse with an amperage rating
• Fuse (blown fuse) other than that specified. Improvising or us-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ing a fuse with the wrong amperage rating
a. Push the OFF/LOCK switch. may cause extensive damage to the electri-
b. Install a new fuse of the correct amperage cal system, cause the lighting and ignition
rating. systems to malfunction and could possibly
c. Set on the switches to verify if the electrical cause a fire.
circuit is operational. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d. If the fuse immediately blows again, check
4. Install:
the electrical circuit.
• Front cover
Fuses
Amperage
Q’ty
rating 4-1.
Main 40 A 1
8-229
EAS31006
deteriorate.
REPLACING THE ECU (Engine Control Unit) • Charging time, charging amperage and
1. Push the ON/start switch (to OFF). charging voltage for a VRLA (Valve Regu-
2. Replace the ECU (Engine Control Unit). lated Lead Acid) battery are different from
3. Clean the throttle bodies and reset the ISC those of conventional batteries. The VRLA
(Idle Speed Control) learning value. (Valve Regulated Lead Acid) battery should
Refer to “CHECKING AND CLEANING THE be charged according to the appropriate
THROTTLE BODIES” on page 7-9. charging method. If the battery is over-
4. Check: charged, the electrolyte level will drop con-
• Engine idling speed siderably. Therefore, take special care
Start the engine, warm it up, and then mea- when charging the battery.
sure the engine idling speed.
TIP
Engine idling speed Since VRLA (Valve Regulated Lead Acid) bat-
1100–1300 r/min teries are sealed, it is not possible to check the
charge state of the battery by measuring the
EAS30552
CHECKING AND CHARGING THE BATTERY specific gravity of the electrolyte. Therefore, the
EWA13290 charge of the battery has to be checked by mea-
WARNING suring the voltage at the battery terminals.
Batteries generate explosive hydrogen gas 1. Remove:
and contain electrolyte which is made of poi- • Battery cover
sonous and highly caustic sulfuric acid. Refer to “GENERAL CHASSIS (1)” on page
Therefore, always follow these preventive 4-1.
measures: 2. Disconnect:
• Wear protective eye gear when handling or • Battery leads
working near batteries. (from the battery terminals)
• Charge batteries in a well-ventilated area. ECA13640
• Keep batteries away from fire, sparks or NOTICE

open flames (e.g., welding equipment, First, disconnect the negative battery lead
lighted cigarettes). “1”, and then positive battery lead “2”.
• DO NOT SMOKE when charging or han-
dling batteries.
• KEEP BATTERIES AND ELECTROLYTE 1
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
2
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes and
get immediate medical attention. 3. Remove:
INTERNAL • Battery
• Drink large quantities of water or milk fol- Refer to “GENERAL CHASSIS (1)” on page
lowed with milk of magnesia, beaten egg or 4-1.
vegetable oil. Get immediate medical atten- 4. Check:
tion. • Battery charge
ECA13661 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTICE a. Connect a digital circuit tester to the battery
• This is a VRLA (Valve Regulated Lead Acid) terminals.
battery. Never remove the sealing caps be-
cause the balance between cells will not be
maintained and battery performance will
8-230
• Positive tester probe 

(refer to the appropriate charging method)
EWA13300
positive battery terminal
• Negative tester probe  WARNING
negative battery terminal Do not quick charge a battery.
ECA13671
TIP
NOTICE
• The charge state of a VRLA (Valve Regulated
Lead Acid) battery can be checked by measur- • Do not use a high-rate battery charger
ing its open-circuit voltage (i.e., the voltage since it forces a high-amperage current
when the positive battery terminal is discon- into the battery quickly and can cause bat-
nected). tery overheating and battery plate damage.
• No charging is necessary when the open-cir- • If it is impossible to regulate the charging
cuit voltage equals or exceeds 12.8 V. current on the battery charger, be careful
not to overcharge the battery.
b. Check the charge of the battery, as shown in • When charging a battery, be sure to remove
the charts and the following example. it from the vehicle. (If charging has to be
Example done with the battery mounted on the vehi-
Open-circuit voltage = 12.0 V cle, disconnect the negative battery lead
Charging time = 6.5 hours from the battery terminal.)
Charge of the battery = 20–30 %
• To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
• Make sure the battery charger lead clips are
in full contact with the battery terminal and
that they are not shorted. A corroded bat-
tery charger lead clip may generate heat in
the contact area and a weak clip spring may
A. Open-circuit voltage (V) cause sparks.
B. Charging time (hours) • If the battery becomes hot to the touch at
C. Relationship between the open-circuit volt- any time during the charging process, dis-
age and the charging time at 20 C (68 F) connect the battery charger and let the bat-
D. These values vary with the temperature, the tery cool before reconnecting it. Hot
condition of the battery plates, and the elec- batteries can explode!
trolyte level. • As shown in the following illustration, the
open-circuit voltage of a VRLA (Valve Reg-
ulated Lead Acid) battery stabilizes about
30 minutes after charging has been com-
pleted. Therefore, wait 30 minutes after
charging is completed before measuring
the open-circuit voltage.
A. Open-circuit voltage (V)

B. Charging condition of the battery (%)
C. Ambient temperature 20 C (68 F)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Charge:
• Battery
8-231
g. Measure the battery open-circuit voltage after

leaving the battery unused for more than 30
minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a constant voltage
A. Open-circuit voltage (V) charger
B. Time (minutes) a. Measure the open-circuit voltage prior to
C. Charging charging.
D. Ambient temperature 20 C (68 F) TIP
E. Check the open-circuit voltage. Voltage should be measured 30 minutes after
the engine is stopped.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a variable-current b. Connect a charger and ammeter to the bat-
(voltage) charger tery and start charging.
a. Measure the open-circuit voltage prior to c. Make sure that the current is higher than the
charging. standard charging current written on the bat-
TIP tery.
Voltage should be measured 30 minutes after TIP
the engine is stopped. If the current is lower than the standard charging
current written on the battery, this type of battery
b. Connect a charger and ammeter to the bat- charger cannot charge the VRLA (Valve Regu-
tery and start charging. lated Lead Acid) battery. A variable voltage
TIP charger is recommended.
Set the charging voltage to 16–17 V. If the set-
ting is lower, charging will be insufficient. If too d. Charge the battery until the battery’s charg-
high, the battery will be over-charged. ing voltage is 15 V.
TIP
c. Make sure that the current is higher than the Set the charging time at 20 hours (maximum).
standard charging current written on the bat-
tery. e. Measure the battery open-circuit voltage after
TIP leaving the battery unused for more than 30
If the current is lower than the standard charging minutes.
current written on the battery, set the charging 12.8 V or more --- Charging is complete.
voltage adjust dial at 20–24 V and monitor the 12.7 V or less --- Recharging is required.
amperage for 3–5 minutes to check the battery. Under 12.0 V --- Replace the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Standard charging current is reached
Battery is good. 6. Install:
• Standard charging current is not reached • Battery
Replace the battery.
d. Adjust the voltage so that the current is at the 4-1.
standard charging level. 7. Connect:
e. Set the time according to the charging time • Battery leads
suitable for the open-circuit voltage. (to the battery terminals)
ECA13630
f. If charging requires more than 5 hours, it is
NOTICE
advisable to check the charging current after
a lapse of 5 hours. If there is any change in First, connect the positive battery lead “1”,
the amperage, readjust the voltage to obtain and then the negative battery lead “2”.
the standard charging current.
8-232
B
2
1 L/W Sb
B
G/B
8. Check: 1. Positive battery terminal

• Battery terminals 2. Negative battery terminal
Dirt  Clean with a wire brush. 3. Positive tester probe
Loose connection  Connect properly. 4. Negative tester probe
9. Lubricate:
• Battery terminals A. XP530E-A/XP530-A
B. XP530D-A
Dielectric grease Result
Continuity
10.Install: (between “3” and “4”)
• Battery cover
Refer to “GENERAL CHASSIS (1)” on page Starter relay
4-1.
EAS30553
CHECKING THE RELAYS

Check each switch for continuity with the digital
circuit tester. If the continuity reading is incor-
rect, replace the relay. G/R Br

90890-03243 1 2
eter
YU-A1927 1. Positive battery terminal
2. Negative battery terminal
1. Disconnect the relay from the wire harness.
3. Positive tester probe
2. Connect the digital circuit tester () and bat-
4. Negative tester probe
tery (12 V) to the relay terminal as shown.
Check the relay operation.
Result
Continuity
Starting circuit cut-off relay (between “3” and “4”)
A
L/W Sb
B
G/Y
8-233
Headlight relay (dimmer) Radiator fan motor relay

First step:
1
3
2
Y/R R/W
L/B Y/B Br
L
Y
Br/R
Y/W
1. Positive battery terminal

1. Positive tester probe 2. Negative battery terminal
2. Negative tester probe 3. Positive tester probe
3. Negative tester probe 4. Negative tester probe
Result Result
Continuity Continuity
(between “1” and “2”) (between “3” and “4”)
No continuity
(between “1” and “3”)
Fuel injection system relay
Second step:
3
5 +
4
2 1 L/Y R/B
R/L
L/B Y/B Br
R
Y
Y/W

1. Positive battery terminal 2. Negative battery terminal
2. Negative battery terminal 3. Positive tester probe
3. Positive tester probe 4. Negative tester probe
5. Negative tester probe Result
Continuity
Result (between “3” and “4”)
Continuity
No continuity
8-234
Sidestand relay Steering lock relay
Lg L/Y B G/Y
G/Y R
G/R R/G
1. Positive battery terminal 1. Positive battery terminal

2. Negative battery terminal 2. Negative battery terminal
3. Positive tester probe 3. Positive tester probe
Result Result
Turn signal/hazard relay Ignition system relay
Br R/G L/Y R
Br/W Br/L
R/G R

Result Result
8-235
Brake light relay (for XP530D-A) Second step:
3
5 +
4
2 1
B G/Y Lg/B P/W Br/R Br
B
Br Br

Result
No continuity Result
(between “3” and “4”) No continuity
Continuity
Windshield drive unit relay (down) (for
XP530D-A)
First step:
Windshield drive unit relay (up) (for
1 XP530D-A)
First step:
3
1
2
3
P/W Br/R Br
2
B
Br
P/B Br/R Br
B
R
Result 3. Negative tester probe
Continuity
Result
No continuity
Continuity
No continuity
8-236
Second step: Seat heater relay (control) (for XP530D-A)

First step:
3
5 + 1
4
2 1 2
P/B Br/R Br
G Y/B Br
B
R
Y

2. Negative battery terminal 1. Positive tester probe
3. Positive tester probe 2. Negative tester probe
5. Negative tester probe Result
Continuity
Result (between “1” and “2”)
No continuity
(between “3” and “4”) Second step:
Continuity
(between “3” and “5”) 3
+
Seat heater relay (power) (for XP530D-A) 4
3 2 1
4 + G Y/B Br
Y
2 1
B/W Br
Y
2. Negative battery terminal
R
2. Negative battery terminal Result
3. Positive tester probe No continuity
4. Negative tester probe (between “3” and “4”)
Result Smart key system relay (unlock)

Continuity First step:
(between “3” and “4”) A
1
3
2
P/W Br/R R/G
B
Br/R
8-237
1 3
3 5
4
2 1
2
P/W Br/R R/G P/W Br/R R/G
B B
Br/R,R Br/R,R
1 3
3 5
4
2 1
2
P/W Br/R R/G P/W Br/R R/G
B B
R R
1. Positive tester probe 1. Positive battery terminal

2. Negative tester probe 2. Negative battery terminal
A. XP530E-A
B. XP530-A
C. XP530D-A A. XP530E-A
B. XP530-A
Result C. XP530D-A
Continuity
(between “1” and “2”) Result
No continuity No continuity
Continuity
Second step: (between “3” and “5”)
3 Smart key system relay (lock)
5 First step:
4
2 1
1
3
P/W Br/R R/G
B
Br/R
2
P/B Br/R R/G
B
Br

8-238
Result Diode 1
(between “1” and “2”) Positive tester probe 
No continuity Green/Red, Blue/White “1”
(between “1” and “3”) Negative tester probe 
Red/Green “2”
Second step: No continuity
Positive tester probe 
3 Red/Green “2”
5 Negative tester probe 
4 Green/Red, Blue/White “1”
2 Diode 2
1 Continuity
P/B Br/R R/G Positive tester probe 
B Red/Black “3”
Br Negative tester probe 
Blue/Yellow “4”
No continuity
1. Positive battery terminal Positive tester probe 
2. Negative battery terminal Blue/Yellow “4”
Negative tester probe 
Red/Black “3”
Diode 3
5. Negative tester probe Continuity
Positive tester probe 
Result Black/White “5”
No continuity Negative tester probe 
(between “3” and “4”) Red/White “6”
Continuity No continuity
(between “3” and “5”) Positive tester probe 
Red/White “6”
EAS30555
CHECKING THE DIODES Black/White “5”
1. Check: Diode 5
• Diodes Continuity
Out of specification  Replace. Positive tester probe  Pink “7”
Digital circuit tester (CD732) Pink/Black “8”
90890-03243 No continuity
Model 88 Multimeter with tachom- Positive tester probe 
eter Pink/Black “8”
YU-A1927 Negative tester probe  Pink
“7”
TIP Diode (fuse box)
The digital circuit tester reading are shown in the Continuity
following table. Positive tester probe 
Green/Yellow “9”
Negative tester probe  Sky
blue “10”
No continuity
Positive tester probe  Sky blue
“10”
Green/Yellow “9”
8-239
R/G
G/R
L/W
1 9 10
A. Diode 1
B. Diode 2
4 C. Diode 3
D. Diode 5
L/Y E. Diode (fuse box)
R/B ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the diode from the wire harness.
3 b. Connect the digital circuit tester () to the di-
ode terminals as shown.
c. Check the diode for continuity.
d. Check the diode for no continuity.
TIP
6 When you switch the positive and negative tes-
ter probes, the readings in the above chart will
R/W be reversed.
B/W ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30557
5
CHECKING THE SPARK PLUG CAPS
spark plug caps.
1. Check:
8 • Spark plug cap resistance
P/B
Resistance
P 7.50–12.50 k
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
7
a. Remove the spark plug cap from the spark
plug lead.
b. Connect the digital circuit tester () to the
spark plug cap as shown.
90890-03243
eter
YU-A1927
8-240
Secondary coil resistance

12.00–18.00 k
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the igni-
tion coil.
b. Connect the digital circuit tester () to the ig-
nition coil as shown.
90890-03243
c. Measure the spark plug cap resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
eter
EAS30558
YU-A1927
CHECKING THE IGNITION COIL
1. Check: • Positive tester probe 
• Primary coil resistance Spark plug lead “1”
• Negative tester probe 
Out of specification  Replace. Spark plug lead “2”
Primary coil resistance
1.87–2.53  2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ignition coil connectors from
the ignition coil terminals.
b. Connect the digital circuit tester () to the ig-
nition coil as shown. 1

90890-03243
c. Measure the secondary coil resistance.
eter
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
YU-A1927
EAS30556
• Positive tester probe CHECKING THE IGNITION SPARK GAP

Orange “1” 1. Check:
Red/Black “2” • Ignition spark gap
Out of specification  Perform the ignition
system troubleshooting, starting with step (5).
Refer to “TROUBLESHOOTING” on page
8-7.
Minimum ignition spark gap
6.0 mm (0.24 in)
2
TIP
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
c. Measure the primary coil resistance. a. Disconnect the spark plug cap from the spark
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
plug.
2. Check: b. Connect the ignition checker “1” as shown.
• Secondary coil resistance
8-241
Ignition checker
90890-06754
Oppama pet–4000 spark checker
YM-34487
c. Push the ON/start switch and the engine stop

switch to “ ”.
d. Measure the ignition spark gap “a”.
b. Measure the crankshaft position sensor re-

sistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30561
CHECKING THE LEAN ANGLE SENSOR

1. Remove:
• Lean angle sensor
(from the bracket.)
2. Spark plug cap 2. Check:
e. Crank the engine by pushing the ON/start • Lean angle sensor output voltage
switch and gradually increase the spark gap Out of specification  Replace.
until a misfire occurs. Operating angle
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
65 
Output voltage up to operating
EAS30560
angle
CHECKING THE CRANKSHAFT POSITION
0.4–1.4 V
SENSOR
Output voltage over operating an-
1. Disconnect: gle
• Crankshaft position sensor coupler 3.7–4.4 V
(from the wire harness)
2. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Crankshaft position sensor resistance a. Connect the test harness– lean angle sensor
Out of specification  Replace the crank- (6P) “1” to the lean angle sensor and wire
shaft position sensor/stator assembly. harness as shown.
Crankshaft position sensor resis- b. Connect the digital circuit tester (DC V) to the
tance test harness– lean angle sensor (6P).
228–342  Digital circuit tester (CD732)
90890-03243
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Model 88 Multimeter with tachom-
a. Connect the digital circuit tester () to the eter
crankshaft position sensor coupler as shown. YU-A1927
Test harness– lean angle sensor
Digital circuit tester (CD732) (6P)
90890-03243 90890-03209
Model 88 Multimeter with tachom- Test harness– lean angle sensor
eter (6P)
YU-A1927 YU-03209
• Positive tester probe  • Positive tester probe 

Gray “1” Yellow/Green (wire harness color)
• Negative tester probe  • Negative tester probe 
Black “2” Black/Blue (wire harness color)
8-242
EAS30566
CHECKING THE STATOR COIL

1. Disconnect:
65 • Stator coil coupler
65
(from the wire harness)
2. Check:
• Stator coil resistance
Out of specification  Replace the stator coil.
Stator coil resistance
0.224–0.336 
c. Push the ON/start switch.
d. When turn the lean angle sensor to 65. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
e. Measure the lean angle sensor output volt- a. Connect the digital circuit tester () to the sta-
age. tor coil coupler as shown.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30562 90890-03243
CHECKING THE STARTER MOTOR Model 88 Multimeter with tachom-
OPERATION eter
1. Check: YU-A1927
• Starter motor operation
Does not operate  Perform the electric • Positive tester probe 
starting system troubleshooting, starting with White “1”
step (4). White “2”
Refer to “TROUBLESHOOTING” on page
8-17. • Positive tester probe 
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ White “1”
a. Connect the positive battery terminal “1” and • Negative tester probe 
White “3”
starter motor lead “2” with a jumper lead “3”.
EWA13810
WARNING • Positive tester probe 

White “2”
• A wire that is used as a jumper lead must • Negative tester probe 
have at least the same capacity of the bat- White “3”
tery lead, otherwise the jumper lead may
burn.
• This check is likely to produce sparks,
therefore, make sure no flammable gas or
fluid is in the vicinity.
b. Measure the stator coil resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30680
CHECKING THE RECTIFIER/REGULATOR

b. Check the starter motor operation.
1. Check:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Battery charging voltage
Out of specification  Check the stator coil
condition. If the stator coil does not have a
problem, replace the rectifier/regulator.
8-243
Refer to “CHECKING THE STATOR COIL”

on page 8-243. Digital circuit tester (CD732)
90890-03243
Battery charging voltage Model 88 Multimeter with tachom-
above 14 V at 5000 r/min eter
YU-A1927
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the digital circuit tester (AC V) to the • Positive tester probe 
battery terminal as shown. Green “1”
Digital circuit tester (CD732) Black “2”
90890-03243
eter
YU-A1927

Battery positive terminal “1”
Battery negative terminal “2”
2 b. Move the fuel sender float to empty fuel tank

position “3” and full fuel tank position “4” level
position.
1 4
3
b. Start the engine and let it run at approximate-
ly 5000 r/min.
c. Measure the rectifier/regulator input voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30573 c. Measure the fuel sender resistance.

CHECKING THE FUEL SENDER ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Fuel pump • Fuel pump
(from the fuel tank) Refer to “FUEL TANK” on page 7-1.
2. Check: EAS31557
CHECKING THE FUEL METER/FUEL LEVEL

• Fuel sender resistance
WARNING INDICATOR
Out of specification  Replace the fuel
This model is equipped with a self-diagnosis de-
pump.
vice for the fuel level detection circuit.
Sender unit resistance (full) 1. Check:
10.0–14.0  • Fuel meter/fuel level warning indicator “1”
Sender unit resistance (empty) (Push the ON/start switch.)
267.0–273.0  Fuel meter/fuel level warning indicator comes
on for a few seconds, then goes off  Fuel
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ meter/fuel level warning indicator is OK.
a. Connect the digital circuit tester () to the fuel Fuel meter/fuel level warning indicator does
pump terminals as shown. not come on  Replace the meter assembly.
8-244
Fuel meter/fuel level warning indicator flash- ature sensor is dropped, replace it.
es eight times, then goes off for 3 seconds in 2. Check:
a repeated cycle (malfunction detected in fuel • Coolant temperature sensor resistance
sender)  Replace the fuel pump assembly. Out of specification  Replace.
Coolant temperature sensor re-
sistance
2512–2777  at 20 C (2512–
1 2777  at 68 F)
Coolant temperature sensor re-
sistance
210–220  at 100 C (210–220 
at 212 F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EAS30577 a. Connect the digital circuit tester () to the
CHECKING THE RADIATOR FAN MOTOR coolant temperature sensor terminals as
1. Check: shown.
• Radiator fan motor
Faulty/rough movement  Replace. Digital circuit tester (CD732)
90890-03243
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the radiator fan motor coupler eter
from the wire harness. YU-A1927
b. Connect the battery (DC 12 V) as shown.
• Positive battery terminal  b. Immerse the coolant temperature sensor “1”
Blue “1” in a container filled with coolant “2”.
• Negative battery terminal  TIP
Black “2”
Make sure the coolant temperature sensor ter-
minals do not get wet.
c. Place a thermometer “3” in the coolant.
3
1
2
c. Measure the radiator fan motor movement.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d. Heat the coolant or let it cool down to the

EAS30578
CHECKING THE COOLANT TEMPERATURE specified temperature.

SENSOR e. Measure the coolant temperature sensor re-
1. Remove: sistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Coolant temperature sensor
Refer to “THERMOSTAT” on page 6-7. 3. Install:
EWA14130
• Coolant temperature sensor
WARNING
• Handle the coolant temperature sensor Coolant temperature sensor
with special care. 18 N·m (1.8 kgf·m, 13 lb·ft)
T.
R.
• Never subject the coolant temperature sen-

sor to strong shocks. If the coolant temper-
8-245
EAS30581
7-13.
CHECKING THE THROTTLE POSITION
SENSOR EAS30582
1. Remove: CHECKING THE ACCELERATOR POSITION
• Throttle position sensor SENSOR
(from the throttle bodies) 1. Remove:
EWA16690
• Accelerator position sensor
WARNING EWA16700
• Handle the throttle position sensor with WARNING

special care. • Handle the accelerator position sensor with
• Never subject the throttle position sensor special care.
to strong shocks. If the throttle position • Never subject the accelerator position sen-
sensor is dropped, replace it. sor to strong shocks. If the accelerator po-
2. Check: sition sensor is dropped, replace it.
• Throttle position sensor maximum resistance 2. Check:
Out of specification  Replace the throttle • Accelerator position sensor maximum resis-
position sensor. tance
Out of specification  Replace the accelera-
Resistance
1.20–2.80 k tor position sensor.
Resistance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1.08–2.52 k
a. Connect the digital circuit tester () to the
throttle position sensor terminals as shown. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the digital circuit tester () to the ac-
90890-03243 celerator position sensor terminals as shown.
Model 88 Multimeter with tachom- Digital circuit tester (CD732)
eter 90890-03243
YU-A1927 Model 88 Multimeter with tachom-
eter
• Positive tester probe  YU-A1927
Blue “1”
Black/Blue “2” • Positive tester probe 
Blue “1”
Black/Blue “2”
2 1
1 2
B B/L W L
R L B/L W
b. Measure the throttle position sensor maxi-

mum resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Measure the accelerator position sensor
3. Install: maximum resistance.
• Throttle position sensor ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP
When installing the throttle position sensor, ad- 3. Install:
just its angle properly. Refer to “ADJUSTING • Accelerator position sensor
THE THROTTLE POSITION SENSOR” on page
8-246
EAS30592
from the wire harness.
CHECKING THE THROTTLE SERVO MOTOR b. Connect the battery (DC V) to the windshield
1. Remove: drive unit terminals “1” as shown.
• Air filter case
Refer to “GENERAL CHASSIS (3)” on page A
4-17.
2. Check:
• Throttle valve operation 1 1
Throttle valves do not fully close  Replace R Br
the throttle bodies.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect two C-size batteries to the throttle
servo motor terminals “1” as shown.
ECA20060
NOTICE
A
Do not use a 12 V battery to operate the throt-
tle servo motor. 2
2
TIP
Do not use old batteries to operate the throttle
servo motor.
A
1
2
1 1
1 R Br
3V
B
1
2 2
2
1
3V
A. Check that the throttle valves “2” fully close.

B. Check that the throttle valves “2” open.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS32448 A. Check that the windshield drive unit arms “2”

CHECKING THE WINDSHIELD DRIVE UNIT up.
(for XP530D-A) B. Check that the windshield drive unit arms “2”
1. Check: down.
• Windshield drive unit operation ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Faulty/rough movement  Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the windshield drive unit coupler
8-247
EAS31016
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE GRIP WARMERS (for
a. Disconnect the seat heater coupler from the
XP530D-A)
wire harness.
b. Connect the digital circuit tester () to the
grip warmers.
seat heater coupler as shown.
1. Check:
• Grip warmer resistance Digital circuit tester (CD732)
Out of specification  Replace the grip 90890-03243
warmer. Model 88 Multimeter with tachom-
eter
Grip warmer resistance (L) YU-A1927
1.2–1.4  (XP530D-A)
Grip warmer resistance (R)
1.2–1.5  (XP530D-A) • Positive tester probe 
Blue “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Black “2”
a. Disconnect the grip warmer coupler from the
wire harness.
b. Connect the digital circuit tester () to the grip
warmer coupler as shown.
90890-03243
eter
YU-A1927 2 1

Black “1” c. Measure the seat heater resistance.
• Negative tester probe  ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Black “2”
EAS30593
CHECKING THE INTAKE AIR PRESSURE

SENSOR
1. Check:
• Intake air pressure sensor output voltage
2 1
Intake air pressure sensor output
voltage
3.57–3.71 at 103.0 kPa (3.57–3.71
at 1.03 kgf/cm², 3.57–3.71 at 14.9
psi)
c. Measure the grip warmer resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the test harness S– pressure sensor
EAS32449
“1” to the intake air pressure sensor and wire
CHECKING THE SEAT HEATER (for XP530D- harness as shown.
A) ECA20040
1. Check: NOTICE
• Seat heater resistance Pay attention to the installing direction of the
Out of specification  Replace the seat as- test harness S-pressure sensor (3P) coupler
sembly. “a”.
Seat heater resistance b. Connect the digital circuit tester to the test
8.8–10.8  harness S– pressure sensor (3P).
8-248
Digital circuit tester (CD732) Intake air temperature sensor re-

90890-03243 sistance
Model 88 Multimeter with tachom- 5400–6600  at 0 C (5400–6600
eter  at 32 F)
YU-A1927 Intake air temperature sensor re-
Test harness S– pressure sensor sistance
(3P) 289–391  at 80 C (289–391  at
90890-03207 176 F)
Test harness S– pressure sensor
(3P) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
YU-03207 a. Connect the digital circuit tester () to the in-
take air temperature sensor terminal as
• Positive tester probe  shown.
Pink/White (wire harness color)
• Negative tester probe  Digital circuit tester (CD732)
Black/Blue (wire harness color) 90890-03243
eter
YU-A1927
b. Immerse the intake air temperature sensor

a “1” in a container filled with water “2”.
TIP
Make sure that the intake air temperature sensor
terminals do not get wet.
1
c. Place a thermometer “3” in the water.
c. Push the ON/start switch.

d. Measure the intake air pressure sensor out- 3
put voltage. 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30594
CHECKING THE INTAKE AIR

TEMPERATURE SENSOR 2
1. Remove:
• Intake air temperature sensor
d. Heat the water or let it cool down to the spec-
(from the air filter case.)
EWA14110 ified temperatures.
WARNING e. Measure the intake air temperature sensor
• Handle the intake air temperature sensor resistance.
with special care. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Never subject the intake air temperature 3. Install:

sensor to strong shocks. If the intake air • Intake air temperature sensor
temperature sensor is dropped, replace it.
Intake air temperature sensor bolt
2. Check: 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
T.
• Intake air temperature sensor resistance

R.
Out of specification  Replace. EAS30681
CHECKING THE FUEL INJECTOR

1. Check:
• Fuel injector resistance
Out of specification  Replace the fuel injec-
tor.
8-249
Resistance • Positive tester probe 

12.0  positive battery terminal “1”
negative battery terminal “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the fuel injector coupler from wire
harness.
b. Connect the digital circuit tester () to the fuel
injector coupler. 1

90890-03243
Model 88 Multimeter with tachom- 2
eter
YU-A1927
• Positive tester probe  c. Measure the smart key battery voltage.

Injector terminal “1” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Injector terminal “2” EAS31555
CHECKING THE BUZZER

1. Check:
• Buzzer operation
Buzzer does not sound  Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the buzzer coupler from the wire
harness.
b. Connect the battery (12 V) to the buzzer cou-
pler as shown.
• Positive battery lead 
c. Measure the fuel injector resistance. Yellow “1”
• Negative battery lead 
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Pink “2”
EAS31553
CHECKING THE SMART KEY BATTERY

2 1
1. Check:
• Smart key battery voltage P Y
Out of specification  Replace the smart key
battery.
Smart key battery voltage
2.7–3.2 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the smart key battery from the smart c. Check that the buzzer sounds.
key. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Connect the digital circuit tester (DC V) to the
EAS32440
smart key battery as shown. CHECKING THE SEAT/FUEL LID LOCK
Digital circuit tester (CD732) SOLENOID
90890-03243 1. Check:
Model 88 Multimeter with tachom- • Seat/fuel lid lock solenoid
eter Faulty/rough movement  Replace.
YU-A1927 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the seat/fuel lid lock solenoid
8-250
from the wire harness.

• Positive battery terminal 
Brown “1”
• Negative battery terminal 
Red “2”
Br R
1 2
c. Check the seat/fuel lid lock solenoid move-
ment.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS32450
CHECKING THE STORAGE COMPARTMENT

LID LOCK SOLENOID (for XP530-A/XP530D-
A)
1. Check:
• Storage compartment lid lock solenoid
Faulty/rough movement  Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the storage compartment lid lock
solenoid from the wire harness.
• Positive battery terminal 
Brown “1”
• Negative battery terminal 
Black “2”
Br B
1 2
c. Check the storage compartment lid lock sole-
noid movement.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-251
TROUBLESHOOTING
TROUBLESHOOTING......................................................................................9-1
GENERAL INFORMATION ........................................................................9-1
1
STARTING FAILURE/HARD STARTING...................................................9-1
INCORRECT ENGINE IDLING SPEED .....................................................9-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ............................9-2
FAULTY CLUTCH ......................................................................................9-2
OVERHEATING .........................................................................................9-2
2
OVERCOOLING.........................................................................................9-3
POOR BRAKING PERFORMANCE...........................................................9-3
FAULTY FRONT FORK LEGS...................................................................9-3
UNSTABLE HANDLING .............................................................................9-3
FAULTY LIGHTING OR SIGNALING SYSTEM .........................................9-3
TROUBLESHOOTING AT THE ABS WARNING LIGHT ...........................9-4
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

3
(ECU) ...............................................................................................................9-5
SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION
4
SYSTEM)...................................................................................................9-5
COMMUNICATION ERROR WITH THE METER ....................................9-12
DIAGNOSTIC CODE: SENSOR OPERATION TABLE ............................9-12
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE .......................9-15
EVENT CODE TABLE ....................................................................................9-17

TROUBLESHOOTING DETAILS (EVENT CODE)...................................9-19 5
6
7
8
9
TROUBLESHOOTING
EAS20090
Electrical system
TROUBLESHOOTING 1. Battery
EAS30599
• Discharged battery
GENERAL INFORMATION • Faulty battery
TIP 2. Fuse(s)
The following guide for troubleshooting does not • Blown, damaged or incorrect fuse
cover all the possible causes of trouble. It should • Improperly installed fuse
be helpful, however, as a guide to basic trouble- 3. Spark plug(s)
shooting. Refer to the relative procedure in this • Incorrect spark plug gap
manual for checks, adjustments, and replace- • Incorrect spark plug heat range
ment of parts. • Fouled spark plug
• Worn or damaged electrode
EAS31258 • Worn or damaged insulator
STARTING FAILURE/HARD STARTING • Faulty spark plug cap
Engine 4. Ignition coil
1. Cylinder(s) and cylinder head • Cracked or broken ignition coil body
• Loose spark plug • Broken or shorted primary or secondary coils
• Loose cylinder head or cylinder • Faulty spark plug lead
• Damaged cylinder head gasket 5. Ignition system
• Damaged cylinder gasket • Faulty ECU (engine control unit)
• Worn or damaged cylinder • Faulty crankshaft position sensor
• Incorrect valve clearance • Broken generator rotor woodruff key
• Improperly sealed valve 6. Switches and wiring
• Incorrect valve-to-valve-seat contact • Faulty engine stop switch
• Incorrect valve timing • Broken or shorted wiring
• Faulty valve spring • Faulty front, rear or both brake light switches
• Seized valve • Faulty ON/start switch
2. Piston(s) and piston ring(s) • Faulty sidestand switch
• Improperly installed piston ring • Improperly grounded circuit
• Damaged, worn or fatigued piston ring • Loose connections
• Seized piston ring 7. Starting system
• Seized or damaged piston • Faulty starter motor
3. Air filter • Faulty starter relay
• Improperly installed air filter • Faulty starting circuit cut-off relay
• Clogged air filter element • Faulty starter clutch
4. Crankcase and crankshaft EAS30601
• Improperly assembled crankcase INCORRECT ENGINE IDLING SPEED
• Seized crankshaft Engine
Fuel system 1. Cylinder(s) and cylinder head
1. Fuel tank • Incorrect valve clearance
• Empty fuel tank • Damaged valve train components
• Clogged rollover valve 2. Air filter
• Clogged fuel tank breather hose • Clogged air filter element
• Deteriorated or contaminated fuel Fuel system
• Clogged or damaged fuel hose 1. Throttle body (-ies)
2. Fuel pump • Damaged or loose throttle body joint
• Faulty fuel pump • Improperly synchronized throttle bodies
• Faulty fuel injection system relay • Improperly adjusted engine idling speed (idle
• Damaged vacuum hose adjusting screw)
• Improperly routed hose • Improper throttle grip free play
3. Throttle body (-ies) • Flooded throttle body
• Deteriorated or contaminated fuel
• Sucked-in air
9-1
TROUBLESHOOTING
Electrical system 2. Engine oil

1. Battery • Incorrect oil level
• Discharged battery • Incorrect oil viscosity (low)
• Faulty battery • Deteriorated oil
2. Spark plug(s) 3. Primary sliding sheave
• Incorrect spark plug gap • Seized primary sliding sheave
• Incorrect spark plug heat range Poor starting performance
• Fouled spark plug 1. V-belt
• Worn or damaged electrode • V-belt slips
• Worn or damaged insulator • Oil or grease on the V-belt
• Faulty spark plug cap 2. Primary sliding sheave
3. Ignition coil • Faulty operation
• Broken or shorted primary or secondary coils • Worn pin groove
• Faulty spark plug lead • Worn pin
• Cracked or broken ignition coil Poor speed performance
4. Ignition system 1. V-belt
• Faulty ECU (engine control unit) • Oil or grease on the V-belt
• Faulty crankshaft position sensor 2. Primary pulley weight(s)
• Broken generator rotor woodruff key • Faulty operation
EAS30602
• Worn primary pulley weight
POOR MEDIUM-AND-HIGH-SPEED 3. Primary fixed sheave
PERFORMANCE • Worn primary fixed sheave
Refer to “STARTING FAILURE/HARD START- 4. Primary sliding sheave
ING” on page 9-1. • Worn primary sliding sheave
Engine 5. Secondary fixed sheave
1. Air filter • Worn secondary fixed sheave
• Clogged air filter element 6. Secondary sliding sheave
Fuel system • Worn secondary sliding sheave
1. Throttle body EAS30607
• Faulty throttle body OVERHEATING

2. Fuel pump Engine
• Faulty fuel pump 1. Clogged coolant passages
EAS30849
• Cylinder head and piston(s)
FAULTY CLUTCH • Heavy carbon buildup
Engine operates but scooter will not move 2. Engine oil
1. V-belt • Incorrect oil level
• Bent, damaged or worn V-belt • Incorrect oil viscosity
• Slipping V-belt • Inferior oil quality
2. Primary pulley cam and primary pulley slider Cooling system
• Damaged or worn primary pulley cam 1. Coolant
• Damaged or worn primary pulley slider • Low coolant level
3. Clutch spring(s) 2. Radiator
• Damaged clutch spring • Damaged or leaking radiator
4. Transmission gear(s) • Faulty radiator cap
• Damaged transmission gear • Bent or damaged radiator fin
Clutch slips 3. Water pump
1. Clutch • Damaged or faulty water pump
• Improperly assembled clutch 4. Thermostat
• Fatigued clutch spring • Thermostat stays closed
• Worn clutch weight 5. Oil cooler
• Worn friction plate • Clogged or damaged oil cooler
• Worn clutch plate 6. Hose(s) and pipe(s)
• Damaged hose
9-2
TROUBLESHOOTING
• Improperly connected hose • Incorrect oil viscosity

• Damaged pipe • Incorrect oil level
• Improperly connected pipe EAS30611
Fuel system UNSTABLE HANDLING
1. Throttle body (-ies) 1. Handlebar
• Damaged or loose throttle body joint • Bent or improperly installed handlebar
2. Air filter 2. Steering head components
• Clogged air filter element • Improperly installed upper bracket
Chassis • Improperly installed lower bracket
1. Brake(s) (improperly tightened ring nut)
• Dragging brake • Bent steering stem
Electrical system • Damaged ball bearing or bearing race
1. Spark plug(s) 3. Front fork leg(s)
• Incorrect spark plug gap • Uneven oil levels (both front fork legs)
• Incorrect spark plug heat range • Unevenly tensioned fork spring (both front
2. Ignition system fork legs)
• Faulty ECU • Broken fork spring
EAS30608 • Bent or damaged inner tube
OVERCOOLING • Bent or damaged outer tube
Cooling system 4. Swingarm
1. Thermostat • Worn bearing or bushing
• Thermostat stays open • Bent or damaged swingarm
EAS30609
5. Rear shock absorber assembly
POOR BRAKING PERFORMANCE • Faulty rear shock absorber spring
• Worn brake pad • Leaking oil or gas
• Worn brake disc 6. Tire(s)
• Air in hydraulic brake system • Uneven tire pressures (front and rear)
• Leaking brake fluid • Incorrect tire pressure
• Faulty brake caliper kit • Uneven tire wear
• Faulty brake caliper seal 7. Wheel(s)
• Loose union bolt • Incorrect wheel balance
• Damaged brake hose • Deformed cast wheel
• Oil or grease on the brake disc • Damaged wheel bearing
• Oil or grease on the brake pad • Bent or loose wheel axle
• Incorrect brake fluid level • Excessive wheel runout
8. Frame
EAS30610
• Bent frame
FAULTY FRONT FORK LEGS • Damaged steering head pipe
Leaking oil • Improperly installed bearing race
• Bent, damaged or rusty inner tube
• Cracked or damaged outer tube EAS30612
• Improperly installed oil seal FAULTY LIGHTING OR SIGNALING SYSTEM

• Damaged oil seal lip Headlight does not come on
• Incorrect oil level (high) • Faulty headlight assembly
• Loose damper rod bolt • Too many electrical accessories
• Damaged damper rod bolt copper washer • Hard charging
• Cracked or damaged cap bolt O-ring • Incorrect connection
Malfunction • Improperly grounded circuit
• Bent or damaged inner tube • Poor contacts (dimmer switch)
• Bent or damaged outer tube • Faulty headlight relay (dimmer)
• Damaged fork spring • Faulty ignition system relay
• Worn or damaged outer tube bushing • Faulty remote control unit
• Bent or damaged damper rod
9-3
TROUBLESHOOTING
Tail/brake light does not come on

• Faulty brake light switch
• Too many electrical accessories
• Incorrect connection
• Faulty tail/brake light
• Faulty ignition system relay
• Faulty remote control unit
Turn signal does not come on
• Faulty turn signal switch
• Faulty turn signal/hazard relay
• Burnt-out turn signal bulb
• Incorrect connection
• Damaged or faulty wire harness
• Improperly grounded circuit
• Faulty battery
• Blown, damaged or incorrect fuse
Turn signal blinks slowly
• Faulty turn signal switch
• Incorrect turn signal bulb
Turn signal remains lit
Turn signal blinks quickly
• Incorrect turn signal bulb
Horn does not sound
• Improperly adjusted horn
• Damaged or faulty horn
• Faulty horn switch
• Faulty battery
• Blown, damaged or incorrect fuse
• Faulty wire harness
EAS30848
TROUBLESHOOTING AT THE ABS

WARNING LIGHT
Refer to “BASIC PROCESS FOR TROUBLE-
SHOOTING” on page 8-169.
9-4
(ECU)
EAS20162
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU)

EAS31794
SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)

TIP
For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-61.
Fault Probable cause of Fail-safe system

Item Vehicle symptom
code No. malfunction operation
P0030 O2 sensor heater • Open or short cir- (When the O2 sensor Display only (If the O2
(defective heater con- cuit in wire harness. does not operate sensor does not oper-
troller detected) • Disconnected cou- because the exhaust ate, O2 feedback is
pler. temperature is low) not carried out).
• Defective O2 sensor Increased exhaust Cruise control system
heater controller emissions. cannot be operated.
(Malfunction in Fuel learning cannot
ECU). be carried out.
• Broken or discon-
nected lead in O2
sensor heater.
P0107 [P0107] Intake air [P0107] Low voltage Engine idling speed is –N is fixed.
P0108 pressure sensor of the intake air pres- unstable. Fuel is not cut off due
(ground short circuit sure sensor circuit Engine response is to the intake air pres-
detected) (0.5 V or less) poor. sure difference.
[P0108] Intake air [P0108] High voltage Loss of engine power. Intake air pressure is
pressure sensor of the intake air pres- Increased exhaust fixed to 101.3 [kPa].
(open or power short sure sensor circuit emissions. O2 feedback is not
circuit detected) (4.8 V or more) carried out.
• Defective coupler ISC feedback is not
between intake air carried out.
pressure sensor and ISC learning is not
ECU. carried out.
• Open or short cir- Cruise control system
cuit in wire harness cannot be operated.
between intake air
pressure sensor and
ECU.
• Defective intake air
pressure sensor.
• Malfunction in ECU.
P0112 [P0112] Intake air [P0112] Low voltage Engine is difficult to The intake air temper-
P0113 temperature sensor of the intake air tem- start. ature is fixed to 20
(ground short circuit perature sensor circuit Increased exhaust [C].
detected) (0.1 V or less) emissions. O2 feedback is not
[P0113] Intake air [P0113] High voltage Engine idling speed is carried out.
temperature sensor of the intake air tem- unstable. ISC feedback is not
(open or power short perature sensor circuit carried out.
circuit detected) (4.8 V or more) ISC learning is not
• Defective coupler carried out.
between intake air
temperature sensor
and ECU.
• Open or short cir-
cuit in wire harness
between intake air
temperature sensor
and ECU.
• Improperly installed
intake air tempera-
ture sensor.
• Defective intake air
temperature sensor.
9-5
(ECU)
P0117 [P0117] Coolant tem- [P0117] Low voltage Engine is difficult to The radiator fan motor
P0118 perature sensor of the coolant temper- start. relay is on only when
(ground short circuit ature sensor circuit Increased exhaust the vehicle is traveling
detected) (0.1 V or less) emissions. at low speeds.
[P0118] Coolant tem- [P0118] High voltage Engine idling speed is O2 feedback is not
perature sensor (open of the coolant temper- unstable. carried out.
or power short circuit ature sensor circuit ISC feedback is not
detected) (4.9 V or more) carried out.
• Defective coupler ISC learning is not
between coolant carried out.
temperature sensor The coolant tempera-
and ECU. ture is fixed to 60 [C].
• Open or short cir- Cruise control system
cuit in wire harness cannot be operated.
between coolant
temperature sensor
and ECU.
coolant temperature
sensor.
• Defective coolant
temperature sensor.
P0122 [P0122] Throttle posi- [P0122, P0222] Low Engine idling speed is Change in the throttle
P0123 tion sensor (ground voltage of the throttle high. opening is 0 (transient
P0222 short circuit detected) position sensor circuit Engine idling speed is control is not carried
P0223 [P0123] Throttle posi- (0.25 V or less) unstable. out).
P2135 tion sensor (open or [P0123, P0223] High Engine response is D–j is fixed.
power short circuit voltage of the throttle poor. Throttle opening is
detected) position sensor circuit Loss of engine power. fixed to 125[].
[P0222] Throttle posi- (4.75 V or more) Deceleration is poor. Intake air pressure is
tion sensor (ground [P2135] Difference in Increased exhaust fixed to 101.3 [kPa].
short circuit detected) output voltage 1 and emissions. O2 feedback is not
[P0223] Throttle posi- output voltage 2 of the Vehicle cannot be carried out.
tion sensor (open or throttle position sen- driven. Fuel is not cut off due
power short circuit sor to the throttle open-
detected) • Defective coupler ing.
[P2135] Throttle posi- between throttle Output is restricted.
tion sensor (output position sensor and ISC feedback is not
voltage deviation ECU. carried out.
error) • Open or short cir- ISC learning is not
cuit in wire harness carried out.
between throttle Cruise control system
position sensor and cannot be operated.
ECU.
throttle position sen-
sor.
• Defective throttle
position sensor.
9-6
(ECU)
P0132 O2 sensor (short cir- [P0132] High voltage Increased exhaust O2 feedback is not
cuit detected (power of the O2 sensor cir- emissions. carried out.
short circuit)) cuit (4.8 V or more) O2 feedback learning
No normal signals are • Improperly installed is not carried out.
received from the O2 O2 sensor. Cruise control system
sensor. • Defective coupler cannot be operated.
between O2 sensor
and ECU.
between O2 sensor
and ECU.
• Incorrect fuel pres-
sure.
• Defective O2 sensor.
P0201 [P0201] Fuel injector • Defective coupler Loss of engine power. O2 feedback is not
P0202 #1 (malfunction in fuel between injector Engine is difficult to carried out.
injector #1) and ECU. start. ISC feedback is not
[P0202] Fuel injector • Open or short cir- Engine cannot be carried out.
#2 (malfunction in fuel cuit in wire harness started. ISC learning is not
injector #2) between injector Engine stops. carried out.
and ECU. Engine idling speed is Cruise control system
• Defective injector. unstable. cannot be operated.
• Malfunction in ECU. Increased exhaust
• Improperly installed emissions.
injector.
P0335 Crankshaft position • Defective coupler Engine cannot be Does not operate.
sensor (no normal between crankshaft started. ISC feedback is not
signals are received position sensor and carried out.
from the crankshaft ECU. ISC learning is not
position sensor) • Open or short cir- carried out.
between crankshaft
position sensor and
ECU.
crankshaft position
sensor.
• Malfunction in gen-
erator rotor.
• Defective crank-
shaft position sen-
sor.
P0351 Ignition coil (open or • Defective coupler Engine stops. Injection to the appli-
short circuit detected between ignition coil Loss of engine power. cable cylinder group is
in the primary lead of and ECU. Engine is difficult to cut off.
the ignition coil.) • Open or short cir- start. O2 feedback is not
cuit in wire harness Engine cannot be carried out.
between ignition coil started. ISC feedback is not
and ECU. Engine idling speed is carried out.
• Improperly installed unstable. ISC learning is not
ignition coil. Increased exhaust carried out.
• Defective ignition emissions. Cruise control system
coil. cannot be operated.
9-7
(ECU)
Fault Item Probable cause of Vehicle symptom Fail-safe system
P0500 Rear wheel sensor • Open or short cir- Vehicle speed is not Vehicle speed dis-
(no normal signals are cuit in wire harness displayed on the played on the meter =
received from the rear between rear wheel meter. 0 [km/h]
wheel sensor) sensor and ABS Engine stalls when O2 feedback is not
unit. the vehicle is deceler- carried out.
• Open or short cir- ating to a stop. Fuel cut-off control
cuit in wire harness Engine idling speed is when the rear wheel
between ABS unit high. sensor or neutral
and ECU. Indication of the neu- switch malfunctions is
• Open or short cir- tral indicator light is carried out.
cuit in wire harness incorrect. ISC feedback is not
between neutral Engine cannot be carried out.
switch and ECU. restarted when the ISC learning is not
• Open or short cir- transmission is in carried out.
cuit in wire harness gear even with the Traction control does
between clutch clutch lever squeezed. not work.
switch and ECU. Engine idling speed is Cruise control system
• Defective rear wheel unstable. cannot be operated.
sensor. Increased exhaust
• Defective neutral emissions.
switch. Traction control does
• Defective clutch not work.
switch.
• Improper adjust-
ment of clutch lever.
P0507 Engine idling speed is • Malfunction when Engine idling speed is O2 feedback is not
too high. writing the ISC too high. carried out.
learning values. ISC learning is not
• Air leak in the intake carried out.
passage.
• Defective throttle
valve.
P0560 Rectifier/regulator: • Battery overcharg- Engine is difficult to O2 feedback is not
malfunction detected. ing (defective recti- start. carried out.
Charging voltage is fier/regulator). Increased exhaust Cruise control system
abnormal. • Battery overcharg- emissions. cannot be operated.
ing (broken or dis- Battery performance
connected lead in has deteriorated or
rectifier/regulator battery is defective.
wire harness).
• Battery over-dis-
charging (broken or
disconnected lead in
charging system).
• Battery over-dis-
charging (defective
rectifier/regulator).
P0564 Cruise control setting • Open or short cir- Cruise control system Cruise control system
switch “RES+” (no cuit in wire harness. cannot be operated. cannot be operated.
normal signals are • Defective cruise
received from the control setting
front wheel sensor) switch.
Cruise control setting
switch “SET–” (no
normal signals are
received from the
front wheel sensor)
9-8
(ECU)
P056C Cruise control cancel • Open or short cir- Cruise control system Cruise control system
switch (open or short cuit in wire harness. cannot be operated. cannot be operated.
circuit detected) • Defective cruise
control setting
switch.
P0601 Faulty ECU memory. • Malfunction in ECU. Engine cannot be Engine cannot be
(When this malfunc- started. started.
tion is detected in the
ECU, the fault code
number might not
appear on the tool
display.)
P0606 Internal malfunction in • Malfunction in ECU. Engine cannot be Engine cannot be
ECU (When this mal- started. started.
function is detected in Engine response is Ignition and injection
the ECU, the fault poor. are not carried out.
code number might Loss of engine power. Judgment for other
not appear on the tool fault codes is not car-
display.) ried out.
Load control is not
carried out. (The fuel
injection system relay,
headlight relay (dim-
mer), and other relays
are all turned off.)
The CO adjustment
mode and diagnostic
mode cannot be acti-
vated.
Output is restricted.
Cruise control system
cannot be operated.
P062F EEPROM fault code • CO adjustment Increased exhaust CO adjustment value
number (an error is value is not properly emissions. for the faulty cylinder
detected while read- written. Engine cannot be = 0 (default value)
ing or writing on • ISC learning value is started or is difficult to ISC learning values =
EEPROM) not properly written. start. Default values
• OBD memory value Engine idling speed is OBD memory value is
is not properly writ- unstable. initialized.
ten. OBD memory value is Initialization of O2
• Malfunction in ECU. not correct. feedback learning
value.
Cruise control system
cannot be operated.
P0638 YCC-T drive system: • Defective coupler Engine response is O2 feedback is not
open or short circuit. between throttle poor. carried out.
YCC-T drive system: servo motor and Loss of engine power. YCC-T evacuation is
malfunction detected. ECU. Engine idling speed is activated.
• Open or short cir- unstable. Output is restricted.
cuit in wire harness ISC feedback is not
between throttle carried out.
servo motor and ISC learning is not
ECU. carried out.
• Defective throttle Cruise control system
servo motor. cannot be operated.
• Throttle servo motor
is stuck (mecha-
nism or motor).
• Blown electric throt-
tle valve fuse.
9-9
(ECU)
Fault Item Probable cause of Vehicle symptom Fail-safe system
P0657 Fuel system voltage • Open or short cir- Engine is difficult to Monitor voltage = 12
(incorrect voltage sup- cuit in wire harness start. [V]
plied to the fuel injec- between fuel injec- Increased exhaust O2 feedback is not
tor, fuel pump and fuel tion system relay emissions. carried out.
injection system relay) and ECU.
• Open circuit in wire
harness between
battery and ECU.
• Defective fuel injec-
tion system relay.
P1601 Sidestand switch (no • Defective coupler Engine cannot be Engine is forcefully
normal signals are between starting cir- started. stopped (the injector
received from the sid- cuit cut-off relay and output is stopped).
estand switch) ECU.
between starting cir-
cuit cut-off relay and
ECU.
• Defective coupler
between sidestand
switch and starting
circuit cut-off relay.
between sidestand
switch and starting
circuit cut-off relay.
• Defective sidestand
switch.
P1602 Malfunction in ECU • Open or short cir- Engine idling speed is O2 feedback learning
internal circuit (mal- cuit in wire harness unstable. is not carried out.
function of ECU between ECU and Engine idling speed is O2 feedback learning
power cut-off function) battery. high. value is not written.
• Open or short cir- Increased exhaust Cruise control system
cuit in wire harness emissions. cannot be operated.
between ECU and Engine is difficult to
ignition system start.
relay.
• Blown backup fuse.
P1604 [P1604] Lean angle [P1604] Low voltage Engine cannot be Engine cannot be
P1605 sensor (ground short of the lean angle sen- started. started.
circuit detected) sor circuit (0.2 V or
[P1605] Lean angle less)
sensor (open or [P1605] High voltage
power short circuit of the lean angle sen-
detected) sor circuit (4.8 V or
more)
between lean angle
sensor and ECU.
• Defective lean angle
sensor.
9-10
(ECU)
P2122 [P2122] Accelerator [P2122, P2127] Low Engine response is No change in acceler-
P2123 position sensor (open voltage of the acceler- poor. ator opening. (Tran-
P2127 or ground short cir- ator position sensor Loss of engine power. sient control is not
P2128 cuit detected) circuit (0.25 V or less) Engine idling speed is carried out.)
P2138 [P2123] Accelerator [P2123, P2128] High unstable. Accelerator opening is
position sensor voltage of the acceler- fixed to 0[].
(power short circuit ator position sensor O2 feedback is not
detected) circuit (4.75 V or carried out.
[P2127] Accelerator more) YCC-T evacuation is
position sensor [P2138] Difference in activated.
(ground short circuit output voltage 1 and Fuel cut is prohibited
detected) output voltage 2 of the by accelerator open-
[P2128] Accelerator accelerator position ing.
position sensor (open sensor. Output is restricted.
or power short circuit • Defective coupler ISC feedback is not
detected) between accelera- carried out.
[P2138] Accelerator tor position sensor ISC learning is not
position sensor (out- and ECU. carried out.
put voltage deviation • Open or short cir- Cruise control system
error) cuit in wire harness cannot be operated.
between accelera-
tor position sensor
and ECU.
accelerator position
sensor.
• Defective accelera-
tor position sensor.
P2158 Front wheel sensor • Open or short cir- Engine response is Traction control does
(no normal signals are cuit in wire harness poor. not work.
received from the between front wheel Loss of engine power. Cruise control system
front wheel sensor) sensor and ECU. Engine idling speed is cannot be operated.
• Defective front unstable.
wheel sensor. Traction control does
• Malfunction in ECU. not work.
Traction control sys-
tem indicator on the
meter comes on.
Traction control sys-
tem switch is dis-
abled. (Traction
control system indica-
tor on the meter goes
OFF)
P2195 O2 sensor (no signals • Signal voltage is Increased exhaust O2 feedback is not
are received from the 0.25–0.53 V. emissions. carried out.
O2 sensor.) • Improperly installed O2 feedback learning
O2 sensor. is not carried out.
• Defective coupler Cruise control system
between O2 sensor cannot be operated.
and ECU.
between O2 sensor
and ECU.
• Defective O2 sensor.
9-11
(ECU)
EAS31119
COMMUNICATION ERROR WITH THE METER

U0155 CAN communication Communication Defective meter dis- Grip warmer output:
(Yamaha error (with the meter) between the ECU and play. OFF is fixed.
diagnostic the meter is not possi- Traction control does MAP changeover:
tool) ble not work. State is fixed.
Err (multi- • Defective meter cou- Traction control does
function pler and ECU cou- not work.
meter dis- pler. Meter switch input:
play) • Open or short cir- OFF is fixed.
cuit in the wire har- Cruise control system
ness between the cannot be operated.
meter and the ECU.
• Defective meter.
• Defective ECU.
EAS31057
DIAGNOSTIC CODE: SENSOR OPERATION TABLE

Diagnostic
Item Meter display Procedure
code No.
01 Throttle position sensor sig-

nal 1
• Fully closed position 11–20 Check with throttle valves
fully closed.
• Fully open position 95–106 Check with throttle valves
fully open.
03 Intake air pressure Displays the intake air pres- Operate the throttle while
sure. pushing the ON/start switch.
(If the display value changes,
the performance is OK.)
05 Air temperature Displays the air temperature. Compare the actually mea-
sured air temperature with
the meter display value.
06 Coolant temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured coolant temperature
air temperature. with the meter display value.
When engine is hot: Displays
current coolant temperature.
07 Rear wheel vehicle speed Rear wheel speed pulse Check that the number
pulses 0–999 increases when the rear
wheel is rotated. The number
is cumulative and does not
reset each time the wheel is
stopped.
08 Lean angle sensor Lean angle sensor output Remove the lean angle sen-
voltage sor and incline it more than
65 degrees.
• Upright 0.4–1.4
• Overturned 3.7–4.4
9-12
(ECU)
Diagnostic
code No.
09 Fuel system voltage Fuel system voltage Set the engine stop switch to
(battery voltage) Approximately 12.0 “ ”, and then compare the
actually measured battery
voltage with the tool display
value. (If the actually mea-
sured battery voltage is low,
recharge the battery.)
13 Throttle position sensor sig-
nal 2
• Fully closed position 8–22 Check with throttle valves
fully closed.
• Fully open position 92–108 Check with throttle valves
fully open.
14 Accelerator position sensor
signal 1
• Fully closed position 11–20 Check with throttle grip fully
closed position.
• Fully open position 95–106 Check with throttle grip fully
open position.
15 Accelerator position sensor
signal 2
• Fully closed position 9–23 Check with throttle grip fully
closed position.
• Fully open position 93–109 Check with throttle grip fully
open position.
16 Front wheel vehicle speed Front wheel speed pulse Check that the number
pulses 0–999 increases when the front
wheel is rotated. The number
is cumulative and does not
reset each time the wheel is
stopped.
20 Sidestand switch Extend and retract the sides-
tand (with the transmission in
• Sidestand retracted ON gear).
• Sidestand extended OFF
9-13
(ECU)
Diagnostic
code No.
60 EEPROM fault code display —

• No history 00
• No malfunctions detected
(If the self-diagnosis fault
code P062F is indicated,
the ECU is defective.)
• History exists 01–02 (CO adjustment
value)
• (If more than one cylinder is
defective, the display alter-
nates every two seconds to
show all the detected cylin-
der numbers.
When all cylinder numbers
are shown, the display
repeats the same process.)
11 (Data error for ISC (Idle
Speed Control) learning val-
ues)
12 (O2 feedback learning
value)
13 (OBD memory value)
67 ISC (Idle Speed Control) 00 To erase the ISC (Idle Speed
learning condition display ISC (Idle Speed Control) Control) learning data, set
ISC (Idle Speed Control) learning data has been the engine stop switch from
learning data erasure erased. “ ” to “ ” 3 times in 5 sec-
01 onds.
It is not necessary to erase
the ISC (Idle Speed Control)
learning data.
02
It is necessary to erase the
ISC (Idle Speed Control)
learning data.
70 Control number 0–254 [-] —
80 Cruise control setting switch Push and release the
“RES+” “RES+” side of the cruise
control setting switch.
• Switch is pushed ON
• Switch is released OFF
81 Cruise control setting switch Push and release the “SET–”
“SET–” side of the cruise control set-
ting switch.
• Switch is pushed ON
• Switch is released OFF
9-14
(ECU)
Diagnostic
code No.
82 Cruise control cancel circuit Operate the front brake lever,

rear brake lever, and throttle
• Front brake lever is ON grip.
squeezed
• Front brake lever is OFF
released
• Rear brake lever is ON
squeezed
• Rear brake lever is OFF
released
• Throttle grip is turned past ON
the closed position in the
deceleration direction
• Throttle grip is released OFF
83 Front brake light switch and Operate the front brake lever
rear brake light switch and rear brake lever.
• Front brake lever is ON
squeezed
• Front brake lever is OFF
released
• Rear brake lever is ON
squeezed
• Rear brake lever is OFF
released
87 O2 feedback learning data 00 To erase the O2 feedback
erasure O2 feedback learning data learning data, set the engine
has been erased. stop switch from “ ” to “ ”
01 3 times in 5 seconds.
O2 feedback learning data
has not been erased.
EAS31058
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
Item Actuation Procedure
code No.
30 Ignition coil Actuates the ignition coil five Check that a spark is gener-
times at one-second inter- ated five times.
vals. • Connect an ignition
The “check” indicator on the checker.
Yamaha diagnostic tool
screen come on each time
the ignition coil is actuated.
36 Injector #1 Actuates the injector #1 five Disconnect the fuel pump
times at one-second inter- coupler.
vals. Check that injector #1 is
The “check” indicator on the actuated five times by listen-
Yamaha diagnostic tool ing for the operating sound.
the fuel injector is actuated.
9-15
(ECU)
Diagnostic Item Actuation Procedure
code No.
37 Injector #2 Actuates the injector #2 five Disconnect the fuel pump

times at one-second inter- coupler.
vals. Check that injector #2 is
The “check” indicator on the actuated five times by listen-
Yamaha diagnostic tool ing for the operating sound.
the fuel injector is actuated.
50 Fuel injection system relay Actuates the fuel injection Check that the fuel injection
system relay five times at system relay is actuated five
one-second intervals. times by listening for the
The “check” indicator on the operating sound.
the relay is actuated.
51 Radiator fan motor relay Actuates the radiator fan Check that the radiator fan
motor relay five times at five- motor relay is actuated five
second intervals. times by listening for the
the relay is actuated.
52 Headlight relay (dimmer) Actuates the headlight relay Check that the headlight
(dimmer) five times at five- relay (dimmer) is actuated
second intervals. five times by listening for the
the headlight is actuated.
57 Grip warmer Turns on the grip warmers Check that the grip warmers
for 2 minutes. become warm.
9-16
EVENT CODE TABLE
EAS20164
EVENT CODE TABLE

TIP
The event code numbers listed below cannot be displayed on the meter. To display the event code
numbers, use the Yamaha diagnostic tool.
No. Item Symptom Possible causes Note
192 Intake air pres- Brief abnormality Same as for fault code Perform the inspection
sure sensor detected in the intake number P0107 and items listed for fault code
air pressure sensor P0108 number P0107 and P0108.
193 Throttle position Brief abnormality Same as for fault code Perform the inspection
sensor detected in the throt- number P0122, P0123, items listed for fault code
tle position sensor P0222 and P0223 number P0122, P0123,
P0222 and P0223.
195 Sidestand switch Brief abnormality Same as for fault code Perform the inspection
detected in the ECU number P1601 items listed for fault code
(blue/yellow) input number P1601.
line
196 Coolant tempera- Brief abnormality Same as for fault code Perform the inspection
ture sensor detected a in the number P0117 and items listed for fault code
coolant temperature P0118 number P0117 and P0118.
sensor
197 Intake air temper- Brief abnormality Same as for fault code Perform the inspection
ature sensor detected in the intake number P0112 and items listed for fault code
air temperature sen- P0113 number P0112 and P0113.
sor
203 Lean angle sen- Brief abnormality Same as for fault code Perform the checks and
sor detected in the lean number P1604 and maintenance jobs for fault
angle sensor P1605 code number P1604 and
P1605.
207 Accelerator posi- Brief abnormality Same as for fault code Perform the inspection
tion sensor detected in the accel- number P2122, P2123, items listed for fault code
erator position sensor P2127 and P2128 number P2122, P2123,
P2127 and P2128.
240 O2 sensor During O2 feedback, • Open or short circuit in • If a fault code is occurring,
(Stuck at the the adjustment is the wire harness respond to that first.
upper limit for maintained at the between the sensor * Rarely, Code 240 occurs
adjustment) upper limit and ECU even when the system is
• Drop in fuel pressure functioning properly.
• Clogged fuel injector
• Fault in sensor
• Malfunction in ECU
• Malfunction in the fuel
injection system
241 O2 sensor During O2 feedback, • Open or short circuit in • If a fault code is occurring,
(Stuck at the the adjustment is the wire harness respond to that first.
lower limit for maintained at the between the sensor * Rarely, Code 241 occurs
adjustment) lower limit and ECU even when the system is
• Drop in fuel pressure functioning properly.
• Clogged fuel injector
• Fault in sensor
injection system
9-17
EVENT CODE TABLE
No. Item Symptom Possible causes Note
242 ISC During idling, the Idling engine speed is • Implement diagnostic
(Stuck at the adjustment is main- slow code 67, and check the
upper limit for tained at the upper • Clogged throttle body ISC maintenance request.
adjustment) limit • Poorly adjusted throttle • If a fault code is occurring,
cable respond to that first.
• Poorly adjusted clutch * Rarely, Code 242 occurs
cable even when the system is
• Malfunction in the fuel functioning properly.
injection system
• Dirty or worn spark
plug
• Malfunction in the bat-
tery
243 ISC During idling, the Idling engine speed is • If a fault code is occurring,
(Stuck at the adjustment is main- fast respond to that first.
lower limit for tained at the lower • Poorly adjusted throttle * Rarely, Code 243 occurs
adjustment) limit cable even when the system is
• Poorly adjusted clutch functioning properly.
cable
injection system
plug
tery
244 Poor start- Poor starting/inability • No gasoline • If a fault code is occurring,
ing/inability to to start detected • Malfunction in the fuel respond to that first.
start injection system * Rarely, Code 244 occurs
• Dirty or worn spark even when the system is
plug functioning properly.
tery
245 Engine stop Engine stop detected • No gasoline • If a fault code is occurring,
• Poorly adjusted throttle respond to that first.
cable * Rarely, Code 245 occurs
• Poorly adjusted clutch even when the system is
cable functioning properly.
injection system
plug
tery
246 Cruise control Automatic turning off The cruise control sys- The automatic turning off of
of the cruise control tem will automatically the cruise control system
system detected turn off under the follow- does not indicate a mal-
ing conditions: function in the system.
• Unable to maintain the
set cruising speed
when traveling up a
steep slope
• Wheel slip detected
• Engine stalls
• Sidestand is extended
• Engine stop switch is
set to the “ ” position
9-18
EVENT CODE TABLE
EAS32023
TROUBLESHOOTING DETAILS (EVENT CODE)

Event code No. 30
Event code No. 30
Item Latch up detected.

Fail-safe system
Tool display • 0.4–1.4 (upright)
• 3.7–4.4 (overturned)
Procedure Remove the lean angle sensor and incline it more than 65 degrees.
1 The vehicle has overturned. Raise the vehicle upright. Push the ON/start switch, then
push the OFF/LOCK switch,
and then push the ON/start
switch.
Engine trouble warning light
does not come on  Service is
finished.
comes on  Go to item 2.
2 Installed condition of lean angle Check the installed direction Push the ON/start switch, then
sensor. and condition of the sensor. push the OFF/LOCK switch,
and then push the ON/start
switch.
does not come on  Service is
finished.
3 Defective lean angle sensor. Execute the diagnostic mode. Push the ON/start switch, then
(Code No. 08) push the OFF/LOCK switch,
Replace if defective. and then push the ON/start
Refer to “CHECKING THE switch.
LEAN ANGLE SENSOR” on Engine trouble warning light
page 8-242. does not come on  Service is
finished.
page 8-230.
9-19
EVENT CODE TABLE
Event code No. 70

TIP
If another error code is displayed at the same time, check the other error code first and repair it.
Event code No. 70
Engine forcibly stops when the vehicle is left idling for a long period
Item
of time.

1 Allow to idle for a long period of Push the OFF/LOCK switch. Check whether it is possible to
time. start the engine.
Able to start the engine  Ser-
vice is finished.
Unable to start the engine  Go
to item 2.
ECU” on page 8-211.
9-20
EVENT CODE TABLE
9-21
EAS20091
57. Dimmer/pass switch A. Wire harness
WIRING DIAGRAM 58. Horn switch B. Negative battery sub-wire har-
XP530E-A 2017 59. Menu switch ness
1. Battery charger terminal (OP- 60. Select switch C. Headlight sub-wire harness
TION) 61. Turn signal switch (headlight harness)
2. D-AIR® terminal (OPTION) 62. Rear brake light switch D. Headlight sub-wire harness
3. Seat lock fuse 63. Front turn signal light (left) (front turn signal light harness)
4. Joint coupler 64. Front turn signal light (right)
5. Remote control unit 65. Rear turn signal light (left)
6. OFF/LOCK switch 66. Rear turn signal light (right)
7. Parking/Unlock switch 67. License plate light
8. Buzzer 68. Tail/brake light (left)
9. Turn signal/hazard relay 69. Tail/brake light (right)
10. Storage box light 70. Diode 5
11. Crankshaft position sensor 71. Horn
12. AC magneto 72. Smart key system relay (un-
13. Rectifier/regulator lock)
14. Ignition system relay 73. Seat/fuel lid lock solenoid
15. Battery 74. Smart key system relay (lock)
16. Starter relay 75. Meter assembly
17. Main fuse 76. Smart key system indicator
18. Starter motor light
19. Engine ground 77. Meter light
20. Signaling system fuse 78. Tachometer
21. Ignition fuse 79. Engine trouble warning light
22. Taillight fuse 80. Traction control system indica-
23. Radiator fan motor fuse tor light
24. Fuel injection system fuse 81. Turn signal indicator light (left)
25. Backup fuse 82. Turn signal indicator light (right)
26. Diode (fuse box) 83. ABS warning light
27. ABS motor fuse 84. High beam indicator light
28. ABS solenoid fuse 85. Multi-function display
29. ABS ECU fuse 86. Yamaha diagnostic tool cou-
30. Headlight fuse pler
31. Auxiliary DC jack fuse 87. Radiator fan motor
32. Electronic throttle valve fuse 88. Radiator fan motor relay
33. Steering lock relay 89. ECU (Engine Control Unit)
34. Centerstand lock solenoid 90. Ignition coil
35. Storage box light switch 91. Spark plug
36. Steering lock unit 92. Grip warmer connector
37. Anti-theft alarm (OPTION) 93. Grip warmer (left) (OPTION)
38. Auxiliary DC jack 94. Grip warmer (right) (OPTION)
39. Diode 3 95. Coolant temperature sensor
40. Headlight relay (dimmer) 96. Intake air temperature sensor
41. Headlight control unit 97. Intake air pressure sensor
42. Headlight (low) 98. Lean angle sensor
43. Headlight (high) 99. O2 sensor
44. Auxiliary light 100.Injector #1
45. Diode 1 101.Injector #2
46. Sidestand relay 102.Throttle servo motor
47. Diode 2 103.Accelerator position sensor
48. Fuel injection system relay 104.Throttle position sensor
49. Starting circuit cut-off relay 105.Fuel sender
50. Sidestand switch 106.Fuel pump
51. Handlebar switch (right) 107.ABS ECU (Electronic Control
52. Engine stop switch Unit)
53. ON/start switch 108.Front wheel sensor
54. Hazard switch 109.Rear wheel sensor
56. Handlebar switch (left)
XP530-A 2017 59. Horn switch 112.ABS ECU (Electronic Control
1. Battery charger terminal (OP- 60. Menu switch Unit)
TION) 61. Select switch 113.Front wheel sensor
2. D-AIR® terminal (OPTION) 62. Turn signal switch 114.Rear wheel sensor
3. Seat lock fuse 63. Rear brake light switch 115.Tracking system control unit
4. Joint coupler 64. Front turn signal light (left)
5. Remote control unit 65. Front turn signal light (right) A. Wire harness
6. OFF/LOCK switch 66. Rear turn signal light (left) B. Negative battery sub-wire har-
7. Parking/Unlock switch 67. Rear turn signal light (right) ness
8. Buzzer 68. License plate light C. Headlight sub-wire harness
9. Turn signal/hazard relay 69. Tail/brake light (left) (headlight harness)
10. Storage box light 70. Tail/brake light (right) D. Headlight sub-wire harness
11. Crankshaft position sensor 71. Diode 5 (front turn signal light harness)
12. AC magneto 72. Horn
13. Rectifier/regulator 73. Smart key system relay (un-
14. Ignition system relay lock)
15. Battery 74. Storage compartment lid lock
16. Starter relay solenoid
17. Main fuse 75. Seat/fuel lid lock solenoid
18. Starter motor 76. Smart key system relay (lock)
19. Engine ground 77. Meter assembly
20. Signaling system fuse 78. Smart key system indicator
21. Ignition fuse light
22. Taillight fuse 79. Meter light
23. Radiator fan motor fuse 80. Tachometer
24. Fuel injection system fuse 81. Engine trouble warning light
25. Backup fuse 82. Traction control system indica-
26. Diode (fuse box) tor light
27. ABS motor fuse 83. Turn signal indicator light (left)
28. ABS solenoid fuse 84. Turn signal indicator light (right)
29. ABS ECU fuse 85. ABS warning light
30. Headlight fuse 86. High beam indicator light
31. Auxiliary DC jack fuse 87. Multi-function display
32. Electronic throttle valve fuse 88. Seat heater relay (power) (OP-
33. Steering lock relay TION)
34. Centerstand lock solenoid 89. Seat heater relay (control) (OP-
35. Storage box light switch TION)
36. Steering lock unit 90. Seat heater (OPTION)
37. Anti-theft alarm (OPTION) 91. Yamaha diagnostic tool cou-
38. Auxiliary DC jack pler
39. Diode 3 92. Radiator fan motor
40. Headlight relay (dimmer) 93. Radiator fan motor relay
41. Headlight control unit 94. ECU (Engine Control Unit)
42. Headlight (low) 95. Ignition coil
43. Headlight (high) 96. Spark plug
44. Auxiliary light 97. Grip warmer connector
45. Diode 1 98. Grip warmer (left) (OPTION)
46. Sidestand relay 99. Grip warmer (right) (OPTION)
47. Diode 2 100.Coolant temperature sensor
48. Fuel injection system relay 101.Intake air temperature sensor
49. Starting circuit cut-off relay 102.Intake air pressure sensor
50. Sidestand switch 103.Lean angle sensor
51. Handlebar switch (right) 104.O2 sensor
52. Engine stop switch 105.Injector #1
53. ON/start switch 106.Injector #2
54. Hazard switch 107.Throttle servo motor
55. Mode switch 108.Accelerator position sensor
56. Front brake light switch 109.Throttle position sensor
57. Handlebar switch (left) 110.Fuel sender
58. Dimmer/pass switch 111.Fuel pump
XP530D-A 2017 59. Cruise control power switch 111.Grip warmer (right)
1. Battery charger terminal (OP- 60. Cruise control setting switch 112.Coolant temperature sensor
TION) 61. Dimmer/pass switch 113.Intake air temperature sensor
2. D-AIR® terminal (OPTION) 62. Horn switch 114.Intake air pressure sensor
3. Windshield motor fuse 63. Menu switch 115.Lean angle sensor
4. Joint coupler 64. Select switch 116.O2 sensor
5. Remote control unit 65. Turn signal switch 117.Injector #1
6. OFF/LOCK switch 66. Front turn signal light (left) 118.Injector #2
7. Parking/Unlock switch 67. Front turn signal light (right) 119.Throttle servo motor
8. Buzzer 68. Rear turn signal light (left) 120.Accelerator position sensor
9. Turn signal/hazard relay 69. Rear turn signal light (right) 121.Throttle position sensor
10. Storage box light 70. License plate light 122.Fuel sender
11. Crankshaft position sensor 71. Tail/brake light (left) 123.Fuel pump
12. AC magneto 72. Tail/brake light (right) 124.ABS ECU (Electronic Control
13. Rectifier/regulator 73. Diode 5 Unit)
14. Ignition system relay 74. Horn 125.Front wheel sensor
15. Battery 75. Brake light fuse 126.Rear wheel sensor
16. Starter relay 76. Front brake light switch
17. Main fuse 77. Rear brake light switch A. Wire harness
18. Starter motor 78. Grip cancel switch B. Negative battery sub-wire har-
19. Engine ground 79. Smart key system relay (un- ness
20. Signaling system fuse lock) C. Headlight sub-wire harness
21. Ignition fuse 80. Storage compartment lid lock (headlight harness)
22. Taillight fuse solenoid D. Headlight sub-wire harness
23. Radiator fan motor fuse 81. Seat/fuel lid lock solenoid (front turn signal light harness)
24. Fuel injection system fuse 82. Windshield drive unit
25. Backup fuse 83. Windshield drive unit relay
26. Diode (fuse box) (down)
27. ABS motor fuse 84. Windshield drive unit relay (up)
28. ABS solenoid fuse 85. Tracking system control unit
29. ABS ECU fuse 86. Smart key system relay (lock)
30. Headlight fuse 87. Meter assembly
31. Auxiliary DC jack fuse 88. Smart key system indicator
32. Electronic throttle valve fuse light
33. Steering lock relay 89. Meter light
34. Centerstand lock solenoid 90. Tachometer
35. Storage box light switch 91. Engine trouble warning light
36. Steering lock unit 92. Traction control system indica-
37. Anti-theft alarm (OPTION) tor light
38. Auxiliary DC jack 93. Turn signal indicator light (left)
39. Diode 3 94. Turn signal indicator light (right)
40. Headlight relay (dimmer) 95. Cruise control system indicator
41. Cruise control fuse light
42. Headlight control unit 96. Cruise control setting indicator
43. Headlight (low) light
44. Headlight (high) 97. ABS warning light
45. Auxiliary light 98. High beam indicator light
46. Diode 1 99. Multi-function display
47. Sidestand relay 100.Seat heater relay (power)
48. Diode 2 101.Seat heater relay (control)
49. Fuel injection system relay 102.Seat heater
50. Starting circuit cut-off relay 103.Yamaha diagnostic tool cou-
51. Sidestand switch pler
52. Handlebar switch (right) 104.Radiator fan motor
53. Engine stop switch 105.Radiator fan motor relay
54. ON/start switch 106.ECU (Engine Control Unit)
55. Hazard switch 107.Ignition coil
56. Mode switch 108.Spark plug
57. Brake light relay 109.Grip warmer connector
58. Handlebar switch (left) 110.Grip warmer (left)
EAS30613
COLOR CODE
B Black
Br Brown
Ch Chocolate
Dg Dark green
G Green
Gy Gray
L Blue
Lg Light green
O Orange
P Pink
R Red
Sb Sky blue
W White
Y Yellow
B/G Black/Green
B/L Black/Blue
B/W Black/White
B/Y Black/Yellow
Br/B Brown/Black
Br/L Brown/Blue
Br/R Brown/Red
Br/W Brown/White
Br/Y Brown/Yellow
G/B Green/Black
G/L Green/Blue
G/R Green/Red
G/W Green/White
G/Y Green/Yellow
Gy/G Gray/Green
L/B Blue/Black
L/G Blue/Green
L/R Blue/Red
L/W Blue/White
L/Y Blue/Yellow
Lg/B Light green/Black
Lg/L Light green/Blue
Lg/W Light green/White
O/W Orange/White
P/B Pink/Black
P/W Pink/White
R/B Red/Black
R/G Red/Green
R/L Red/Blue
R/W Red/White
R/Y Red/Yellow
W/G White/Green
W/L White/Blue
W/R White/Red
W/Y White/Yellow
Y/B Yellow/Black
Y/G Yellow/Green
Y/L Yellow/Blue
Y/R Yellow/Red
Y/W Yellow/White
XP530E-A 2017 XP530E-A 2017 XP530E-A 2017 XP530E-A 2017 XP530E-A 2017
WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO
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XP530E-A 2017 XP530E-A 2017 XP530E-A 2017 XP530E-A 2017 XP530E-A 2017
BV1-28197-E0_W.D.indd 2 2017/04/04 14:44:50

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2017 Tmax530DX 서비스매뉴얼 개선판

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2017

IMPORTANT MANUAL INFORMATION

A WARNING indicates a hazardous situation which, if not avoided, could

A NOTICE indicates special precautions that must be taken to avoid

TIP A TIP provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

OIL PUMP OIL PUMP

OIL PUMP CHECKING THE OIL PUMP

ASSEMBLING THE OIL PUMP

2. Check: Recommended lubricant

CHECKING THE RELIEF VALVE

• Oil pump drive chain ECA13890

Cracks/stiffness → Replace the oil pump NOTICE

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

Filling fluid Molybdenum disulfide oil

Lubricant Brake fluid

Special tool B Wheel bearing grease

Tightening torque LS Lithium-soap-based grease

Wear limit, clearance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply locking agent (LOCTITE®).

Engine oil New Replace the part with a new one.

SPECIAL TOOLS ...........................................................................................1-29

VEHICLE IDENTIFICATION NUMBER

YCC-T (Yamaha Chip Controlled Throttle)

YCC-T system outline

1. Accelerator position sensor

OUTLINE OF THE CRUISE CONTROL SYSTEM (for XP530D-A)

Activating and setting the cruise control system

Deactivating the cruise control system

a. Closed position b. Cruise control cancel direction

• Apply the front or rear brake.

Meter displays during cruise control system operation

A. Cruise control system is activated (cruising a. Condition for automatically deactivating

A. Cruise control system is activated (cruising a. Malfunction occurs

OUTLINE OF THE TCS (Traction Control System)

1. Traction control system indicator light

TCS (Traction control system) block diagram

1. Front wheel sensor

Traction control system

1. Traction control system indicator light “ ”

1. Eco indicator “ECO”

TIP Oil change indicator “Oil”

1. V-belt replacement indicator “V-Belt”

To increase the grip warmer temperature, push

To increase the seat heater temperature, push

F-TRIP Display–1 Display–2 Dis-

To reset a tripmeter, use the select switch to se-

NOTICE This function allows you to

3. While the selected item is flashing, push the

4. When you finished resetting, use the select

2. Push the “MENU” switch, use the select

2. Push the “MENU” switch. The unit setting dis-

3. Use the select switch to select “L/100km” or

A.TEMP TRIP-1 TRIP-2

CRNT.F F.AVG RANGE

5. When you finished changing the settings, use

push the “MENU” switch to return to the pre-

4. Push the “MENU” switch, and the minute dig-